Ventilated structural panels and method of construction with ventilated structural panels

ABSTRACT

A multi-plenum structural panel having a top sheet, a middle sheet, and a bottom sheet, each sheet being parallel to the other two. A first plurality of spacing structural elements fixedly attaches the top sheet to the middle sheet. A second plurality of spacing structural elements fixedly attaches the middle sheet to the bottom sheet, such that a yield strength of an assembled multi-plenum structural panel is greater than a sum of individual yield strengths of the top, the middle, and the bottom sheets. An upper plenum is defined by a spacing between the top sheet and the middle sheet. A lower plenum is defined by a spacing between the middle sheet and the bottom sheet. The plurality of spacing structural elements is formed such that a plurality of spaced apart unobstructed pathways are created in each plenum for air to move from at least one edge of the multi-plenum structural panel to at least one of an opposite and an adjacent edge of the multi-plenum structural panel in each plenum.

PRIORITY

This application is a Continuation-in-Part of U.S. patent applicationSer. No. 13/539,919 filed Jul. 2, 2012, which is a Continuation-in-Partof U.S. patent application Ser. No. 13/016,320 filed Jan. 28, 2011, nowU.S. Pat. No. 8,534,018 issued Sep. 17, 2013, which is aContinuation-in-Part of U.S. patent application Ser. No. 12/987,832filed Jan. 10, 2011, now U.S. Pat. No. 8,490,355 issued Jul. 23, 2013,which claims the benefit of U.S. provisional patent application Ser. No.61/376,333, filed Aug. 24, 2010.

FIELD OF THE INVENTION

Residential and commercial sheathing for roofs, walls, floors, andceilings.

BACKGROUND OF THE INVENTION

Sheathing is an essential component of any residential or commercialstructure and provides structural support for roofs, walls and floors,as well as providing a surface of sufficient thickness and strength forthe attachment of roofing materials such as asphalt shingles and metalroofing, siding materials such as wood clapboards or vinyl siding andflooring finishes such as tile, wood, hardwood, laminates, vinyls orcarpets and the like.

Sheathing has traditionally been supplied in 4′×8′ sheets, made ofplywood or OSB, which provide a desirable modular size that can behandled by one worker. The means of attachment depends on the function,thickness and strength requirements of the application and may includemechanical fasteners such as nails or staples and/or adhesives. Roofs,walls, and flooring use sheets of similar sizes, though variedthickness.

Complex, costly, and non-commercially feasible systems have beenproposed to incorporate in some manner ventilation systems intosheathing, but they lack the structural strength and other benefits ofthe present invention.

SUMMARY OF THE INVENTION

Wherefore, it is an object of the present invention to overcome theabove mentioned shortcomings and drawbacks associated with the prior artby providing a ventilated structural panel that allows for ventilationout of and throughout a structure, while simultaneously providing apanel of substantially increased strength, formed of readily availableconstruction materials, for small additional cost.

Another object of the present invention is to provide a ventilatedstructural panel comprising a first sheet, having edges that define ahorizontal axis with a first horizontal edge and a second horizontaledge, and vertical axis with a first vertical edge and a second verticaledge. The panel additionally comprises a second sheet being ofsubstantially the same planar dimensions as the first sheet and havingedges that define a horizontal axis and vertical axis, with a firsthorizontal edge and a second horizontal edge and a first vertical edgeand a second vertical edge; the first and second sheet being parallel inplane and preferably matched in at least one of the vertical axis andthe horizontal axis. A plurality of spacing structural elements fixedlyattaches the first sheet to the second sheet, such that the strength ofthe combined panel is multiple times greater than the combinedindividual strength of the first and second sheet. The ventilatedstructural panel can be at least semi-permeable to the passage of gasesand liquids and the first or bottom sheet of the panel could have one ormore perforations.

The invention is an interlocking construction panel of the same size andapproximate weight of conventional sheathing products that incorporatesintegral ventilation into the structure. The invention may be used as aconventional sheathing and is attached with the same mechanical methodsof nailing and/or adhesives. It is cut and fitted in the same manner. Itinterlocks to provide continuity of strength and ventilation.

The panel is engineered such that it provides the same or superiorstrength of conventional methods of providing construction strength andventilation, with fewer materials. The materials involved in theconstruction of the panel are relatively inexpensive and readilyavailable.

The panels facilitate the use of a wide variety of insulationpossibilities without the need for special consideration forventilation, since the ventilation is integral with the panels. This isuseful for common fiberglass as well as blown products such asfiberglass, Rockwool, cellulose and other products. This is especiallyuseful for the new high performance spray foam expanding insulationsthat are becoming popular because of their high energy efficientperformance and ability to seal infiltration, as the foams can break,plug or destroy conventional foam, plastic, or cardboard ventilationproducts, or intrude into the seams.

The panels could be combined with a multitude of construction materialsand methods in the same way conventional sheathing is used today. Thepanels could be used with conventional soffit and ridge vents by cuttingthe sheathing on the panels for access to the ventilation cavity. Dripedges would have to have an extended leg to cover the side ventilationor it could be blocked with conventional trim.

The panel may be constructed sheets of commonly available 4′×8′sheathing of a thickness determined by structural and roof fasteningrequirements, but may preferably vary from ¼″ to 1½″ in thickness, andmore preferably vary from ⅜″ to ¾″ in thickness. The top and bottomsheets may also vary in thickness.

The two sheets are attached to each other via the spacing structuralelements, with adhesive and/or mechanical means such as nailing,stapling, screwing or machine impressed metal connections, so as toprovide for the transfer of forces.

In essence, the two sheets function as the top and bottom chords of atruss or “I” beam providing superior strength, load carrying capacity,and resistance to deflection (stiffness). As a result, rafter or stud orpurloin spacing may be increased where these panels are used, whichwould reduce material requirements, allowing the elimination of raftersand trusses with the greater spacing.

The spacing structural elements may protrude beyond two contiguous edgesof the panel, and the spacing structural elements may be chamfered toenhance interlocking with adjacent panels. The spacing structuralelements would likewise be indented on the two opposite contiguousedges.

Another embodiment of the invention is a panel comprised of two sheetsof the same size (i.e., same area, but perhaps different thicknesses)connected to each other with a matrix of crossed spacing structuralelements such that the combined entity is one structural panel. Ideally,the panel is the same size as conventional building sheathing, generally4′×8′, but can be of any size or thickness. The sheets are connected soas to be are parallel in plane and matched in the vertical axis, one ontop of the other, such that they can be used in place of traditionalsheathing materials currently used in building construction such asplywood sheathing, OSB sheathing and other composite sheathingmaterials.

In one embodiment, the panel includes a first and a second 4′×8′ sheetof plywood, Oriented Strand Board (OSB), or a composite board of woodand/or plastic, each sheet having a thickness of ¼″ to ¾″ depending onthe application. Roofs would usually consist of the two sheets measuring¼″ to ⅝″ in thickness, depending on strength and span requirements andshingle attachment requirements, and whether the shingles are attachedby staples or nails. Wall sheathing sheet thickness would also be of ¼″to ½″ thickness depending on strength requirements. The top wear layerof the flooring panel will usually have ½″ to ¾″ finish layer dependingon strength requirements and floor covering.

Blocks may be used as the as the spacing structural elements, spacingthe sheets ideally 1½″ from each other. Blocks of a preferably of squareor rectangular form, but the blocks could be of any shape or size,including circular, oval, regular polygons, and irregular shapes. Thespacing can vary depending on the application and ventilationrequirements—more spacing not only enhances ventilation and potentiallyincreases the strength of the assembly, but would also require closerspacing of the blocks or spacers. While panels constructed with blockswould not have the degree of added strength as panels constructed ofelongated members (discussed below), panels constructed of blocks wouldpotentially be less expensive, and provide sufficient increased strengthfor construction with conventional 16 or 24 inch spaced of stud, rafter,truss, or joist is used.

The blocks are generally spaced from 1 to 12 times their own width aparthorizontally and vertically. The specific spacing would depend on thesheet thickness and strength requirements. Blocks were found to onlyincrease the strength of the panel, over the combined individualstrength of the separate sheets comprising the panel, by approximatelyone half the amount of increase as panels utilizing rectangular shapedelongated members. But, using blocks does offer additional constructionpossibilities over rectangular elongated members due to the increasedcontagious space inside a panel offered by using blocks compared tousing a matrix of elongated members. The blocks can be oriented on thesame axis of the sheets or arranged on an angle of preferably 45°; butother orientations, such as 30° or 60°, are possible depending on theapplication. The angled orientation strengthens the plywood or OSBassembly.

Another embodiment of the invention uses spacing structural elementsconsisting of a matrix of rectangular shaped elongated members,preferably comprised of wood members with a square cross section,arranged in layers, each layer oriented perpendicular to the next, andeach layer interconnected to each adjacent layer or adjacent sheet withmechanical means and/or adhesives. The individual elongated memberswould ideally be of ¾″×¾″, but could be larger or smaller. Theindividual elongated members would ideally be long enough to stretchfrom one edge of a sheet to another—this required length varyingdepending on the orientation of the elongated member.

The individual elongated members would be aligned in layers and spaced,parallel, apart from one another preferably between 1 to 18 times thethickness of the elongated member, or ¾″ to 13.5 inches for elongatedmembers with cross sections measuring ¾″×¾″, and more preferably between5 and 16 times the thickness of the elongated member, and mostpreferably between 8 and 12 times the thickness of the elongated member.In another embodiment, each elongated member preferably measures between0.25 and 1.50 inches in height and between 0.25 and 1.50 inches inwidth, more preferably measures between 0.5 and 1.0 inches in height andbetween 0.5 and 1.0 inches in width, and most preferably measuresbetween 0.7 and 0.8 inches in height and between 0.7 and 0.8 inches inwidth. The matrix of elongated members could consist of two layersperpendicular to each other or of multiple successive perpendicularlayers. The matrix can be attached to the sheets either parallel to thesheet axis or on an angle. If an angular orientation is used, theelongated members will be ideally oriented 45° to each axis of bothsheets, but other orientations such as 30° or 60° are possible dependingon the application. The length of the elongated members would be of alength that they stretched from a first edge of a first sheet, to asecond edge of the first sheet. Chamfered elongated members wouldpreferably measure the “edge to edge” length of a sheet, but would beshifted in the direction of the chamfered end. This would allow for theterminal chamfered end of a given elongated member to extend into amating indented end on an abutting panel, while simultaneously allowingroom for a chamfered end on an opposing abutting panel to mate with theindented end of the given elongated member. For example, chamferedmating elongated members would measure 48 inches and 96 inches in anorientation parallel to the sheet axis, and chamfered mating elongatedmembers with a 45° orientation would measure approximately 69 inches or137 inches respectively at the greatest measurements.

In another embodiment, the indented end of an elongated member can havea concave face that will accept all or a portion of the chamfered end ofa mating elongated member. In such an embodiment, the total length ofthe elongated member would preferably be extended by the length in whichthe chamfered end recesses within the concave portion of the indentedend. In the manufacturing of the panels, the elongated members mayinitially be secured to the sheets at lengths greater then required, andthen be trimmed to finished length at a later point in the manufacturingprocess.

The spacing structural elements can also be constructed of elongatedmembers comprised of a plurality of plywood veneers, each veneer beingtypically ⅛″ thick. This plywood matrix would be built up by multiplelayers of veneered elongated members, each veneered elongated memberbeing ideally ½″ to ¾″ thick and spaced from ½″ to 4″ apart. The plywoodmatrix would consist of a first layer of similarly shaped and parallelaligned veneered elongated members, followed by one or more additionallayers laid perpendicular to the first and/or immediately precedinglayer, until a multi-layer plywood matrix of desired thickness isassembled. The veneered elongated members would be attached withadhesives. The resulting plywood matrix can be attached to the sheetseither parallel to the sheet axis or on an angle. If an angularorientation is used, the veneered elongated members will be ideallyoriented 45° to each axis of both sheets, but other orientations such as30° or 60° are possible. The length of the veneered elongated memberswould be similar to that of the non-veneered elongated members abovedepending, depending on the angle of the orientation of the members tothe axis of the sheets, and whether or not the veneered elongatedmembers were chamfered.

In all cases, including spacing blocks and elongated members, thespacing structural elements can protrude on two contiguous edges and bechamfered to enhance interlocking with adjacent panels. The spacingstructural elements can be similarly matingly indented on the twoopposite contiguous edges. The extension is normally less than or equalto 1 inch and ideally between ½″ to ¾″. Additionally, the elongation andindentation may be modified to provide for both contiguous mating ofadjacent panels and a spacing gap between adjacent panels of between0.0625 inches and 0.25 inches. For example, the elongated members lengthcould be increased by, for example, ⅛ inch, or the indentation could bereduced by ⅛ inch, or both, such that the elongated members may matingabut, but the neighboring first and second sheets would be spacedbetween 0.0625 inches and 0.25 inches apart.

The panels with all attributes herein described can also be manufacturedsimilarly to plywood except that the two exterior sheets are insteadseparated by a plurality of elongated members that are spaced apart and,in layers, are laid on to one another perpendicular to each other topermit the passage of air and the transfer of forces. These elongatedmembers function as the spacing structural elements. The number ofelongated members can vary as can the thickness of the elongatedmembers, the width of the elongated members, the spacing of theelongated members and the orientation of the elongated members, forinstance, some may be oriented on an or arranged in the same axis of thesheets.

In all cases where there are matrices of elongated members acting as thespacing structural elements, there may be one, two, three, or fourlayers of elongated members, and where veneer elongated members areused, up to twelve layers may be used. Each additional layer potentiallyadds cost and weight, but also potentially adds strength.

The apparatus may include three layers of elongated members, with twolayers perpendicular to one another and diagonally oriented to the axisof the sheets, and one layer perpendicular to an axis of the sheets. Theapparatus may include three layers of elongated members, with two layersperpendicular to one another and each perpendicular to an axis of thesheets, and one layer diagonally oriented to the axes of the sheets. Theapparatus may include four layers of elongated members, with two layersperpendicular to one another and each perpendicular to an axis of thesheets, and two layers perpendicular to one another and diagonallyoriented to the axes of the sheets. The apparatus may include three orfour layers of elongated members, with each layer oriented perpendicularto the next, and all layers either perpendicular to an axes of thesheets, or all layers diagonally oriented to the axes of the sheets.

In one embodiment, the individual sheets for each panel are spacedequally apart from each other in parallel planes and in the samevertical axis, ideally at a distance of 1½″ from each other, with amatrix of spacing structural elements or members arranged in a crosshatch pattern between the two sheets. The matrix of members wouldideally consist of a first layer of elongated members, each parallel,coplanar, and spaced equally from one another, the first layer beingperpendicular to a second layer of elongated members, each parallel,coplanar, and spaced equally from one another. Each elongated memberwould generally have a square cross section and would extend in lengthfrom one side of the panel to another. For a perpendicular arrangementto the panels, where the panels are spaced at 1½″ apart, this wouldrequire members of ¾″ square faces with lengths of 48″ and 96″, or, ifchamfered, longer, depending on the length of the chamfer.

A layer of screening (e.g., fiberglass, aluminum, plastic) could beaffixed between the first and the second layers of elongated members.This would aid in adhesion and/or fastening of elongated members, andwould facilitate the running of wires through the interior of thepanels.

The elongated members are generally spaced apart from a neighboringelongated member in the same layer from 1 to 12 times their own width,more preferably 3 to 9 times their own width, and most preferably 5 to 7times their own width. The specific spacing would depend on the sheetthickness and strength requirements.

For roofing sheathing, the top layer would preferably be laid in thelong horizontal direction, and have a length of 96 inches, with a repeatof 5⅝″ for shingle attachment if using nails for shingles and the objectis to nail into the elongated member. The panel faces could be stamped,painted, or otherwise visibly marked with the orientation of theunderlying matrix for ease of use by the workman.

The elongated members would usually be oriented perpendicular to oneanother on the same axis of the sheets but other orientations arepossible depending on the application. Testing indicates that theperpendicular orientation significantly strengthens the plywood or OSBassembly more than any other orientation, allowing the use of thinnerexterior sheets. Tests have demonstrated that a strength increase inbending stiffness for an assembly of two ¼ inch sheets, with aperpendicular matrix of two layers of ¾″×¾″ elongated members spaced 5inches apart, has a bending strength approximately 10 times greater thana single sheet of ½″ of plywood alone.

The elongated members of the matrix can consist of square members madeof wood, wood composite, plastic, or similar material, arrangedperpendicular or close to perpendicular for an offset matrix, andinterconnected to each other with mechanical means and/or adhesives.

The individual matrix members would ideally be ¾″×¾″ square, and longenough to extend beyond the panel edge. The size of the elongatedmembers could be larger or smaller and long enough to complete therequired matrix of the sheets, which depends on the orientation, andextend to or beyond one edge. Spacing would be 1 to 12 times thethickness of the elongated member or ¾″ to 9 inches. The matrix of“elongated members” could consist of two layers perpendicular to eachother or multiple layers. The matrix can be attached to the sheetseither parallel to the sheet axis or on an angle of 45°, but otherorientations are possible depending on the application. In all cases, aprovision is made so that the panels interconnect structurally.

For the matrix of elongated members, the elongated members may beindented preferably between ¼″ and ⅝″ and more preferably between ⅜″ and½″ on two contiguous sides, while the other two sides would be extendedby between preferably ¼″ and ⅝″ and more preferably between ⅜″ and ½″with an end member. Additionally, the length of the elongated memberscould be between ½″ and ¾″ longer than the sheet on two contiguous sidesto machine a tongue and groove attachment.

In all embodiments, the spacing structural elements can protrude on twocontiguous edges and may be chamfered to enhance interlocking withadjacent panels. The spacing structural elements would be similarlyindented on the two opposite contiguous edges. The extension wouldnormally be no more than 1 inch and would ideally be between ½″ to ¾″.

Additionally, the one or both sheets can be manufactured from plasticmaterials. These plastic sheeted panels could be used for waterproofapplications such as for roofing or basement wall applications, with oneor both sheets providing a barrier to liquid water and/or water vapor.The joints would be waterproofed with an application of waterproofmastic or tape. The panels could be combined with a multitude ofconstruction materials and methods in the same way conventionalsheathing is used today. Further, a top sheet of one panel may beextended in length and attached such that it overlaps a top sheet of anabutting lower adjacent panel by approximately two to four inches.

The panels could also be manufactured with a perforated bottom sheet tofacilitate ventilation into the panel matrix. The perforations wouldideally be round in shape, sized ¼″ to 1″ in diameter, and arranged in amatrix that is ideally staggered from the adjacent holes with a spacingof 4 to 12 diameters in widths. A layer of screening (e.g., fiberglass,aluminum, plastic) could be affixed along the interior or exteriorsurface of the perforated sheet. The perforations allow for theexhausting of heat, gases, and moisture in attics and non-living spaces.The holes should be such that the panel can still transfer necessarytensile and compressive forces. Both solid and perforated panels can beused together in building assembly, such as a roof.

The panels can facilitate the use of a wide variety of insulationpossibilities without requiring special consideration for ventilationsince the ventilation is integral with the panels. This is useful forcommon fiberglass as well as blown products such as fiberglass,Rockwool, cellulose and other products. This is especially useful forthe new high performance spray foam expanding insulations that arebecoming popular because of their high energy efficient performance andability to seal infiltration.

The panels can be used in both residential and commercial construction.The panels can be used both for on site installation and for factorybuilt modular homes. The panels would be useful for manufactured homesand trailers.

To facilitate construction, the exterior of one or both sheets could bemarked with exterior lines showing the location of the interiorelongated members. The exterior facing sheet could also be of waterproofconstruction and made of waterproof material, such as some form ofplastic, providing for the exposed layer of roofing or wall covering.The top sheet could be sized larger than the bottom sheet such that atop sheet of a first panel would extend to overlap a top sheet of anadjacent, and preferably vertically lower, panel.

In addition to wall and roof sheathing, a flooring system of theventilated structural panels as described would have many benefits.Increased structural strength, spanning capability and reduceddeflection, all of which would result in less materials needed forsupports (joists or trusses or composite joists) and better performancein terms of strength and stiffness. A properly engineered panel could beused for flooring providing a plenum for air distribution providingwarmed and cooled air to be distributed within the floor. The warmed airwould be a desirable characteristic in bathrooms.

A properly engineered panel could be used for flooring providing aplenum for electrical distribution where wires and data communicationcables could be easily run. A properly engineered panel could be usedfor flooring to provide a plenum for radiant heat or forced hot airheat. In this case, one interior surface would generally receive a layerof reflecting material and the spacers would have to be mechanicallyconnected. A properly engineered panel could be used for flooringproviding a plenum for plumbing distribution where pipes, tubes andconduits of proper size could be run. Finally, a flooring system withthis panel construction is naturally quieter than one sheet ofsheathing, providing a nose buffer. This noise buffering benefit wouldalso apply to walls and roofing.

This panel offers three main simultaneous advantages of ventilation,ease of use, and significantly increased strength. First, these panelsoffer ventilation both through the panel sheets and between the panelsheets. In this way, the panels may remove moisture and gasses passingthrough an interior facing sheet, and exhaust them via the continuousair channel created between the sheets by the spacing structuralelements. This air channel will be approximately the width and height ofthe combined width and height of any contiguous surface formed by theventilated structural panels being attached contiguous with one another.Such a large air channel can provide for dramatically increased air flowover the interior facing sheet, and thus dramatically increasedventilation between the interior and exterior—even if only passively. Aparticular advantage this offers is for roofing situations in colderclimates to assist in avoiding ice dams.

A ventilated structural paneled roof provides for ventilation ofmoisture and gasses from the house, and allows a flow of cold air alongthe entire roof surface, in the interior of the panels, to prevent theformation of ice dams. A ventilated structural paneled roof allows forthe entire roof to remain cold in the winter, preventing snow frommelting and ice dams from forming. Any heat that migrates into theventilation plenum is exhausted to the outdoors and does not melt thesnow on the roof. Similarly, ventilation of a wall surface provides thesame benefits noted above. Ventilation in warm climates or during warmmonths can exhaust hot air from the attic space, extending the life ofroofing materials and reducing cooling costs. Also, the inventive panelscan typically achieve ventilation of at least 1/50, when compared tofree, unobstructed end area, greatly exceeding many code requirements.

Second, the structural connection between the two sheets of materialinterconnected with spacing structural elements with adhesive and ormechanical means to transfer shear forces provides that the entireentity becomes a synergistic structural panel with characteristics thatexceed the strength of the individual parts. The top and bottom sheetsact like the flanges on a beam or truss and provide better load carryingstrength, increased span capability and less deflection than theindividual sheets together. Preliminary tests indicate that an assemblyof two ¼ inch sheets of plywood spaced with ¾ inch blocks is 4 timesstronger than just one sheet of ½ inch plywood alone, and two ¼ inchsheets of plywood spaced with a matrix of two ¾″ by ¾″ members can be 10times stronger than just one sheet of ½ inch plywood alone.

This extra strength can be used advantageously to increase the loadcapacity or the length of the unsupported span of the panel, whichreduces the required number of underlying supporting rafters, studs,joists, trusses or purloins, and thus cost of building.

The spacing structural elements material, size, arrangement, thickness,shape and orientation can vary with the application and be adapted tothe specific need of the application.

The plurality spacing structural elements may be arranged such that anumber of linear pathways are created. Each pathway's dimensions arelimited by the dimensions and arrangements of the spacing structuralelements. Utilizing blocks, the pathways may measure in height the fulldistance separating the first and the second sheet; the widthmeasurement is dependent on how far apart the blocks are spaced from oneanother. Utilizing two layers of elongated members, the height of thepathways will measure approximately one half of the distance thatseparates the two sheets. Like the blocks, the width of the pathwaysformed with elongated members will be equal to the distance separatingtwo neighboring elongated members in the same layer. When the two layersof elongated members are arranged perpendicular to each other, thepathways will also be orthogonal. Each pathway allows air to move alongeach pathway unobstructed from at least one edge of the panel to atleast one opposite edge of the panel.

The spacing structural elements can protrude on two contiguous sideswith chamfered edges. The extent of the protrusion could be matched byan indention of the spacing structural elements on the oppositecontiguous two edges which would provide for interlocking of panels.This interlocking of panels would provide structural continuity,increasing structural integrity and minimizing discontinuous deflectionand buckling.

Third, the panel offers significant advantages as to ease of use. Sincethe panel is assembled from readily available building materials, it isfamiliar to the designers, suppliers and trades in terms of size andweight. It can be cut, sized and attached in the same manner ofconventional sheathing. No special tools or skills are needed. Nospecial orientation is needed to ensure the continuity of ventilation,except that the interlocks should be maintained for increased structuralintegrity. Ventilation is maintained without any special considerationsor the use of any special additional materials, except insect andmoisture blocking at the exposed edges.

In another embodiment, the panels can also be constructed as two sheetsseparated by a single layer matrix as described in paragraph 28. Thematrix members can consist of wood, plywood, OSB, medium-densityfiberboard (MDF), other wood composites, plastic or other materials andshaped in a rectangular or most likely square profile and extendingeither the length in the longitudinal direction or the width in theperpendicular direction. Said matrix can be extended on two contiguousedges and chamfered and indented on the opposite two edges to facilitateinterlocking as previously described.

The members would be placed parallel to each other and fastened to boththe top and bottom panels with adhesives and/or mechanical means. Thespacing between members would be from 2 times the thickness anindividual matrix member to 16 times the thickness, but ideally from 4times to 12 times.

The single layer panels could also have perforations as previouslydescribed. The perforations would ideally be round but could also beother shapes such as oblong, oval, square or rectangular or acombination of geometric shapes such as square with rounded corners.

The single layer panels would be useful for wall sheathing applicationswhere the strength of the perpendicular matrix may not be as importantor for some flooring applications. The panels may be used for decoratingconcrete formwork. The orientation of the single layer matrix may beeither longitudinal, lateral, or diagonal depending on the specificapplication.

In an additional embodiment, the panel may be comprised of simply onesheet of panel with a matrix of members, without a second sheet. Itcould be constructed of plywood, OSB, MDF or other materials such asplastic or other composite wood material. In a further additionalembodiment, the matrix of structural spacing elements can also bemanufactured integrally with the panels in either OSB or Plywood orother materials such as MDF, plastics or other wood composites.

Manufacturing integral structural spacing elements, including the matrixof elongated members, would eliminate the need to separately attach theelongated members to each sheet.

Integral raised members would serve as the matrix of elongated members.Two similar sheets may have integral elongated members formedlongitudinally in a first sheet and laterally in a second sheet. The twosheets would then be joined together by adhesives and/or mechanicalmeans, with the matrix members in contact with one another. The finishedflat panel surface would be exposed on the top and bottom. Analternative arrangement would provide for the integral raised members tobe formed at angles to the edges of each respective sheet. Preferablythe integral raised members on the first sheet would be formed suchthat, when they are mated with the integral raised members on the secondsheet, the integral raised members of the first sheet will beperpendicular to the integral raised members of the second sheet.

The same characteristics regarding the size, shape and spacing, andranges therein, of the individual integral elongated members would be asthe elongated members previously described.

In producing panels utilizing integral raised elongated members, plywoodsheets, for example, could be manufactured with a plurality of raisedridges or strips. The raised ridges or strips would function as theintegral elongated members. Two sheets would then be attached to eachother with adhesives and/or mechanical means via the plurality ofintegral elongated members, preferably with the integral elongatedmembers of each sheet in perpendicular orientation to the otherrespective sheet. These panels could also be manufactured from OSB,medium density fiberboard, or other wood composite materials orplastics. These panels and the sheets and integral elongated memberscould be manufactured in multiple steps, or in a single step. Theintegral members could be added during the panel production, or materialcould be removed after production to leave the plurality of elongatedmembers, or the sheet and members could be formed substantiallysimultaneously, including with a mold.

The integral raised elongated members could be made during the panelmanufacturing process with special tools, equipment, rollers, molds andother such means as necessary. The shape of the integral raised membercould take many shapes depending on the tooling, rollers, presses,machinery and other factors, including fiat or round tops, sharp orrounded edges, and flattened or rounded sides. They could have roundedchamfered corners with or without a flat top, they could have angledchamfered corners, they could be rectangular or square in shape.

The integral raised members could be either manufactured simultaneouslywith the sheets or could be shaped by removing material aftermanufacturing a sheet of extra thickness, to accommodate the finishedthickness and integral raised member. Applications of the panelsutilizing integral structural spacing elements would include roofing,flooring, and siding for residential and commercial construction.

The panels with integral matrices' could be manufactured out of Plywood,OSB, MDF or other similar material, including plastics.

The panels with integral matrices' could also have perforations aspreviously described. The perforations would ideally be round but couldalso be other shapes such as oblong, oval, square or rectangular or acombination of geometric shapes such as square with rounded corners.

A further embodiment utilizing integral structural spacing elementswould utilize the first sheet utilizing structural spacing elements, anda second sheet without integral structural spacing elements. In thisembodiment non-integral structural spacing elements can also be used toattach the second sheet to the integral structural spacing elements ofthe first sheet to the second sheet.

A still further embodiment utilizing integral structural spacingelements would utilize both the first and the second sheet, each withintegral structural spacing elements, being connected to one another vianon-integral structural spacing elements.

Yet another embodiment utilizing integral structural spacing elementsinvolves manufacturing the panel such at that the location where theintegral members of the first sheet contact the integral members of thesecond sheet, there is provided that at least one first integral memberof the first sheet may enter into a recess of at least one secondintegral member of the second sheet. The recess in the at least onesecond integral member functioning as a notch for the at least one firstintegral member to be received into. The at least one first and at leastone second integral member could also be adhesively and/or mechanicallyjoined. Additionally the least one first integral member may also beprovided with a recess in which the at least one second integral membermay enter. It is envisioned that the notched recesses may be providedonly on the integrated members of one sheet, could be provided on theintegrated members on both sheets. The notches could be provideduniformly on every elongated member one or both sheets, or could bestaggeredly provided at alternating locations and/or on alternatingintegrated members on one or both sheets. It is also envisioned thatthis notch/recess arrangement could similarly be employed withnon-integrated member embodiments.

This notch like interface between members of multiple layers of membersmay also be utilized for panels including non-integral structuralspacing elements, such as those discussed above.

It should be noted, that the edges of the sheets on any panels in thisapplication may be shaped with tongues on two contiguous edges andcorresponding groves on the remaining two contiguous edges forinterlocking of multiple panels, and/or interlocked with the indentedand overlapped spacing structural elements arrangement described inparagraphs above.

It should also be noted a number of different arrangements arecontemplated in which spacing structural elements create unobstructedpathways for air to move through the panel, from at least one edge ofthe panel to at least one of an opposite and an adjacent edge of thepanel. The height of the unobstructed pathways will normally be equal tothe height of the members. The width of the pathways will normally beequal to the spacing between adjacent members of a common layer. Thenumber of parallel unobstructed pathways created in the panel for air tomove in any one direction will preferably range from between 1 and 30,more preferably between 2 and 25, even more preferably between 4 and 20,yet even more preferably between 5 and 19, and most preferably between 6and 12. If the elongated members were spaced at approximately 16 incheson center, the pathways could be approximately 15 inches in width.Similarly, if the elongated members were spaced at approximately 24inches on center, the pathways could be approximately 23 inches inwidth. In such a way it is achievable to have at least between two tothree unobstructed pathways in a first direction, and between four andsix unobstructed pathways in a second, preferably perpendiculardirection, each measuring approximately ¾″ in height and 15″ to 23″ inwidth. It is also achievable to have at least between four and tenunobstructed pathways in a first direction, and between eight and twentyunobstructed pathways in a second, preferably perpendicular direction,each measuring approximately ¾″ in height and 4″ to 12″ in width.

It should also be noted that the structural spacing elements, and inparticular the elongated members, can be formed in specialized shapes toconvey additional qualities to the structural spacing elements, and thusthe panels. Some specialized shapes include non-perforated andperforated I-beam, truss, skip truss, honeycomb, and corrugated shapedengineered matrix members.

It should further be noted that the invention will preferably beconfigured in one of the four ways following ways. First, a panel couldbe configured as a single sheet with a single layer of elongated membersattached to the sheet, the elongated members arranged parallel with oneanother, and parallel with one axis of the panel and perpendicular tothe other axis. That is, the elongate members could be arranged parallelto a long axis or a short axis of the sheet. In a second panelconfiguration, a single layer of members, as described in the firstalternative, may be arranged between and connected to two sheets. Third,a panel could be configured as at least a double layer of elongatemembers attached to a single sheet, with each layer of elongate membersarranged perpendicular to each adjacent layer of elongate members, atleast one layer arranged parallel to one of a long or a short axis ofthe single sheet, and the elongate members being attached to one anotherwhere the multiple layers of elongate members intersect. Fourth, an atleast double layer of elongate members, as described in the thirdalternative, may be arranged between and connected to two sheets.

To reiterate, the panels, and their constituent sheets and structuralspacing elements, can be constructed or made from porous or non-porouswood, cellulose or other organic material, composite, ferrous, metallic,plastic, or any other material that can be shaped into a flat sheetsand/or the structural spacing elements. The top and bottom sheets andthe structural spacing elements can each be of different materials andthicknesses. The top sheet can be waterproof and the bottom sheet can beperforated to facilitate ventilation.

It should further also be noted that the panel typically has an emptyvolume of approximately 70%, but can range from 40% to 90%, orpreferably from 50% to 80%, or more preferably from 65% to 75%,depending on sheet thickness and structural spacing element size, shape,and placement.

The panels may have a clear, unobstructed airflow of approximately 30%of the area of the end of any panel assembly, but can range from 10% to60%, or preferably from 20% to 50%, or more preferably from 25% to 40%.With the use of special engineered matrix members, discussed in furtherdetail below, the clear, unobstructed airflow can be up to around 75%,but can range from 65% to 85%, or more preferably from 70% to 80% of theend area of the panel assembly.

The clear unobstructed airflow on a panel with solid matrix members of arange from approximately 1/50 to 1/70 when comparing free, unobstructedend area with panel coverage. This depends on roof slope, matrix membersize and spacing. Some building codes require ventilation of 1/300, andsome codes are contemplating requiring or recommending ventilation of1/150. The inventive panels could provide 6 to 12 times greaterventilation performance.

A further object of the present invention is to provide a multi-plenumstructural panel comprising a top sheet, a middle sheet, and a bottomsheet, each sheet having a first horizontal edge and a second horizontaledge, and a first vertical edge and a second vertical edge, all threesheets being parallel in plane, and all three sheets having at least oneof both vertical edges and both horizontal edges aligned along a sameplane; a first plurality of spacing structural elements, fixedlyattaching the top sheet to the middle sheet, and a second plurality ofspacing structural elements fixedly attaching the middle sheet to thebottom sheet, such that the yield strength of the combined multi-plenumstructural panel is greater than the combined individual yield strengthsof the top, the middle, and the bottom sheets; an upper plenum definedby a spacing between the first sheet and the second sheet; a lowerplenum defined by a spacing between the second sheet and the thirdsheet; the plurality of spacing structural elements being formed suchthat a plurality of unobstructed pathways are created in each plenum forair to move from at least one edge of the multi-plenum structural panelto at least one of an opposite and an adjacent edge of the multi-plenumstructural panel.

A yet further object of the present invention is to provide a method ofconstructing a building including one or more multi-plenum structuralpanels comprising a top sheet, a middle sheet, and a bottom sheet, eachsheet having a first horizontal edge and a second horizontal edge, and afirst vertical edge and a second vertical edge, all three sheets beingparallel in plane, and all three sheets having at least one of bothvertical edges and both horizontal edges aligned along a same plane; afirst plurality of spacing structural elements, fixedly attaching thetop sheet to the middle sheet, and a second plurality of spacingstructural elements fixedly attaching the middle sheet to the bottomsheet, such that the yield strength of the combined multi-plenumstructural panel is greater than the combined individual yield strengthsof the top, the middle, and the bottom sheets; an upper plenum definedby a spacing between the first sheet and the second sheet; a lowerplenum defined by a spacing between the second sheet and the thirdsheet; the plurality of spacing structural elements being formed suchthat a plurality of unobstructed pathways are created in each plenum forair to move from at least one edge of the multi-plenum structural panelto at least one of an opposite and an adjacent edge of the multi-plenumstructural panel, the method comprising the steps of supporting the massof one of an interior and exterior wall with the multi-plenum structuralpanel; and connecting one of an air heater and an air conditioner in afluid tight connection with the at least one of the upper and the lowerplenums.

An additional embodiment of the ventilated structural panels can consistof a multi-layered or multi-plenum panel consisting of two plenums,constructed out of three sheets of material separated by structuralspacing elements of preferably blocks. One plenum would supply treated,heated, cooled, humidified, dehumidified, or otherwise conditioned airwhile the other plenum would provide the return air to be conditioned.The original design of the multi-plenum panels provides at least twodistinct and significant benefits—inexpensive multi-location air supplyand return, and much greater strength and structural integrity forsubflooring.

Floor sheathing in residential homes is usually a ⅝ or ¾ inch thickplywood or OSB panel supported on joists or engineered lumber joistswhich are usually spaced at 12 inches on center or 16 inches on center.By contrast, multi-plenum panels are much stronger than regular floorsheathing because its multi-layer design acts like a specialized “I”beam and can provide for long spans with better performance thanstandard sheathing.

The two cavities or plenums could allow for the distribution ofconditioned air to the home or building. In the winter, warm air couldbe pushed into the upper plenum and tapped with vents in each room, asrequired, with a standard commercially available metal or plasticregister placed into the upper plenum.

Return air would be tapped into the lower plenum by a special “plenumtap” system made of metal or plastic that penetrates the top and middlesheets and is fixed into the top and middle sheets with mechanical meansand/or adhesives. The “plenum tap” is now ready to accept a standard,commercially available register.

The same procedure is used for providing cool air distribution, however,to prevent cold floors, the cool supply could be directed to the lowerplenum while the return warmer air is directed through the upper plenum.

In one embodiment an extruded or deposited glob of uncured semi-liquidor foam substance is used as the structural spacing element. The globwould preferably be dispensed at various locations on the surface of thebottom or middle sheet, analogous to various placements of thestructural spacing elements described above, but compositions withgreater strength could be spaced farther apart.

The globs may be extruded alone, or may be used in conjunction with oneor more inserts. The inserts can be shaped as spheres, boxes, rods,spikes, barricade shapes, barred, flanged, or spindle shaped, forexample. The inserts can be three-dimensional shapes as in a sphere or abox, and can be hollow or solid. The inserts can have smooth outersurfaces, or can have protrusions lining their surface. The insertsserve multiple functions. First, they add structural integrity to theglob. Second, they can perform as spacers to prevent the two sheets oneither side of the glob from pressing too close together. That is, theycan mechanically define a minimum clearance between the two adjacentsheets. Also, protrusions or spikes on the surface of the inserts canaid in mechanical connection between two adjacent sheets to one another.The inserts can additionally be used without the globs, and function asthe structural spacing elements themselves.

Though preferably 4×8 feet in measurement, as mentioned above, thesheets can be a variety of sizes. For example, larger sheets could beused and make larger panels in a first step, that could be cut down to4×8 foot or 1×2 meter panels in a second step.

Depending on the different situations, the sheets used in the single ormulti-plenum panels, that is the top, middle, or bottom sheets, could bemade of be made of many and a variety of materials, including but notlimited to: wood and wood fibrous materials; wood fiber panels; woodplywood panels; wood masonite material; plastic materials; fiberglassmaterials; carbon fiber materials, drywall, or some combination ofthereof.

Composite sheets composed of a combination of materials could be made offibers and some binding agent. Said fibers could be wood, cellulose,hemp and other plant materials such as cotton, man-made materials suchas glass, plastics, metal, carbon, etc. The binding agent can be made ofa variety of materials that have the qualities to bind fibers and curewith or without heat or other agents to a usable structural materialwith compressive and tensile strength capabilities.

The sheets can be layers of different materials. For example, the sheetscan be composed of metal or have a metal layer. As another example, thebottom sheet can be drywall or a composite drywall panel where thebottom sheet is composed of the gypsum material placed on a wood orother substrate with tensile strength.

The sheets can be a variety of shapes depending on the use. For example,the sheets can be flat or corrugated or shaped for additional strengthwith geometric patterns. Also, for sheets of composite construction,corrugated materials can also be used to face the sheet.

The sheets can also have insulating properties beyond that of normalplywood or OSB sheets. The sheets can be made of insulating material, orbe a composite sheet of an insulating material with one or more layersof surface materials (like metal or plastic) capable of providing theneeded strength and performance. Additionally, any or all of the sheetsmay have a reflective radiant barrier applied to any surface to furtheraid in insulation.

To aid in microbial, rot, mold, mildew, and pest prevention, any or allsheets may have an anti-fungal, anti-mold, or other effectivepreventative treatment applied to any or all surfaces, includingsurfaces of structural spacing elements. Any wood sheet could be made ofpressure treated lumber if condensation or an application againstconcrete is anticipated. Similarly, any or all sheets can have a paintedor protective coating applied to any surface, depending on the need.

In one production embodiment, the single or multi plenum panels may beconstructed with a 3D printing process, using a variety of availablematerials including fibrous compounds, plastics, carbon fiber, metalcompounds, and other materials suitable for 3D printing applications. 3Dprinting can be utilized for the entire panel construction or forportions of the panels such as a sheet and the structural spacingelements, or any combination thereof.

The structural spacing elements can be made of a variety of materialsand shapes and may include the following but not limited to: wood blocksin any shape and thickness; wood composite blocks in any shape andthickness; wood blocks cut from existing OSB and plywood products; solidplastic materials; adhesives of any type; foams, both closed and opencell; plastics, permeable materials including plastics and foams andadhesives; metal, and composites.

The structural spacing elements may be extruded, molded, cut, welded,pressed, glued, or punched, or otherwise formed.

The structural spacing elements may be spaced at various positions, inaddition to those shown, as required for strength for variousapplications.

The structural spacing elements may be made of various shapes, includingsquare, round, rectangular, triangular, elongate, tubular, truss like,honeycomb, corrugated shapes, and of various thicknesses. These includetubes of round, square or rectangular shapes, and hollow extrusions.

Where the shape of the structural spacing element has an orientation,like tubes, it can be oriented with the shape (e.g. tube) axisperpendicular to the sheet, or with the shape axis parallel to thesheet. For elongate structural spacing elements or sticks in a matrix,the matrix may be oriented perpendicular to each other. Structuralspacing elements with openings may be arranged in a grid type matrix,with structural spacing elements perpendicular to one another, to allowair flow.

Further description will be provided with reference to the Figuresbelow.

BRIEF DESCRIPTION OF THE DRAWINGS

Below is a brief description of the drawings of the inventive panel, inwhich:

FIG. 1 is an exploded depiction of an embodiment of the panel;

FIG. 2 is plan view of an embodiment of the panel;

FIG. 3 is a plan view of an embodiment of the panel depicting theindented space and protruding segments;

FIG. 4 is a close-up iso view of an embodiment of the panel, depictingthe indented space, protruding segments, and chamfered edges;

FIG. 5 is an iso view of the panel mounted on mounting elements;

FIG. 6 is an iso view of an embodiment of the panel utilizing plywoodveneer as spacing structural elements, without showing the top sheet;

FIG. 7 is an iso view of an embodiment of the panel where the spacingstructural elements are aligned diagonally, without showing the topsheet;

FIG. 8 is an iso view of an embodiment of the panel utilizingrectangular blocks as spacing structural elements, without showing thetop sheet;

FIG. 9 is an iso view of an embodiment of the panel utilizing circularblocks as spacing structural elements, without showing the top sheet;

FIG. 10 is an iso view of an embodiment of the panel utilizing squareblocks as spacing structural elements, without showing the top sheet;

FIG. 11 is a close-up iso view of an embodiment of the panel, depictingthe indented space, protruding segments, and chamfered edges;

FIG. 12 is an iso view of an embodiment of the panel with perforationsin one sheet, viewed from the underside;

FIGS. 13A and 13B are side views of two roof arrangements constructedwith the panels;

FIG. 14 is a sectional view of a roof arrangement constructed with thepanels for an unoccupied attic;

FIG. 15A is a sectional view of a roof arrangement constructed with thepanels for an occupied attic;

FIG. 15B is a sectional view of a roof arrangement constructed with thepanels for an unoccupied attic space, where some of the panels areperforated;

FIG. 16 is an iso view of a roof arrangement constructed usingperforated and non-perforated panels;

FIG. 17 is a sectional view of a portion of a roof arrangementconstructed using perforated and non-perforated panels;

FIG. 18 is a sectional view of a house showing a wall, floor, and roofconstructed using the panels;

FIG. 19 is a sectional view of an insulated house showing a wall, floor,and roof constructed using the panels;

FIG. 20 is an exploded view of the portion indicated as portion A inFIG. 19;

FIGS. 20A and 20B are iso-views of panels with a single layer of spacingstructural elements, each having a portion of the top sheet cutaway toshow detail;

FIG. 21 is an iso-view of a panel with a sheet having integrated spacingstructural elements;

FIG. 22 is an iso-view of a panel with two sheets, each havingintegrated elongated members, with a portion of the top sheet cutaway toshow detail;

FIG. 23 is an iso-view of a panel with two sheet, each having integratedelongated members with rectangular profiles;

FIG. 24 is an iso-view of a panel with two sheets, each havingintegrated elongated members with curved profiles;

FIG. 25 is an iso view of a sheet having integrated elongated membersand the plurality of perforations;

FIGS. 26A-26D are profile views of multiple examples of potentialprofiles of integrated elongated members;

FIG. 27 is an iso views of a panel comprised of a single layer ofnesting elongated members.

FIG. 28 is an up close iso view of two elongated members with a notchedattachment;

FIGS. 29-31 are an up close perceptive views of panels using threedifferent embodiments of specialized shaped engineered matrix members,where the top sheet in each panel is not shown;

FIGS. 32-33 are close up perspective views of two additional embodimentsof specialized shaped engineered matrix members;

FIG. 34 is a iso perspective view of a multi-plenum embodiment of thepanel according to the present invention;

FIG. 35 is an exploded iso perspective view of the panel of FIG. 34;

FIG. 36 is a close up partial side view of the panel of FIG. 34;

FIG. 37 is a side view along the long edge of the panel of FIG. 34;

FIG. 38 is a close up side view of an end edge of a panel of FIG. 34that forms a plenum boundary;

FIG. 39 is a cut-away close up iso perspective view of the panel of FIG.34 with a register in exploded view to show detail;

FIGS. 40 and 41 are iso perspective views of the panel of FIG. 34including a plenum tap, with a register in exploded view to show detail,and the blocks omitted;

FIG. 42 is a sectional side view of the panel of FIG. 34 including aplenum tap;

FIG. 43 is an iso perspective view of a plenum tap with selector doorsand levers;

FIGS. 44 and 45 are a sectional side view of buildings with panels ofFIG. 34 used for structural support and conditioned air delivery andreturn;

FIG. 46 is an upward looking sectional view along the sectional linemarked “FIG. 46” in FIG. 44;

FIG. 47 is a side sectional view along the sectional line marked “FIG.47” in FIG. 46;

FIG. 48 is an iso perspective view of the panel of FIG. 34 arranged onjoists;

FIG. 49 is an side sectional perspective view panel of FIG. 34 installedadjacent to the exterior wall of a building;

FIGS. 50 to 52 are close up partial side views of edges of sheets ofjoined adjacent panels of FIG. 34, separated to show detail;

FIG. 53 is an exploded perspective view of the panel of FIG. 34 usingglob spacing structural elements, before compression;

FIG. 54 is a side sectional view of a possible multi-plenum panelconfiguration;

FIG. 55 is a close up view of a glob of FIG. 53, with an embeddedinsert;

FIG. 56 is a perspective view of a spacer;

FIG. 57 is a perspective view of a caged insert with spikes;

FIG. 58 is a perspective view of a barricade shaped insert;

FIG. 59 is a perspective view of a spacer with an elongate mid-section;

FIG. 60 is a perspective view of three through inserts in a middlesheet;

FIG. 61 is a close up side sectional view of a multi-plenum panel wheretwo through inserts pass through a middle sheet and two globs;

FIG. 62 is a close up side sectional view of an integrated throughinsert;

FIGS. 63 and 64 show multiple side sectional views of panels with nailshaped through inserts;

FIGS. 65 and 66 are perspective views of an orthogonal frame used in thepanel;

FIGS. 67 and 68 are perspective views of unitary or bonded orthogonalframe;

FIG. 69 shows a production schematic for scaled up production of thepanels;

FIG. 70 shows a perspective view of a orthogonal matt;

FIG. 71 shows a close up pan view of a belt of the orthogonal matt;

FIG. 72 shows a side view of a block connected to the orthogonal mattand a sheet;

FIG. 73 shows a close up side sectional view of an interlockingmechanism to attach adjacent panels;

FIG. 74 is an partial perspective view of space truss;

FIG. 75 is a partial perspective view of a truss matrix viewed from afirst direction;

FIG. 76 is a side view of the truss matrix of FIG. 75;

FIG. 77 is a partial perspective view of the truss matrix of FIG. 75viewed from a second direction;

FIG. 78 is a partial plan view of the truss matrix of FIG. 75;

FIG. 79 is a partial perspective view of the truss matrix of FIG. 75viewed from a third direction;

FIG. 80 is a close up perspective view of an apex area of the trussmatrix of FIG. 75;

FIGS. 81-83 is a partial perspective views of engineered perforatedmembers used in multi-plenum panels;

FIGS. 84 and 85 are a perspective view and up close perspective view ofa molded middle sheet from above;

FIG. 86 is a close up sectional view of the molded middle sheet of FIG.84;

FIGS. 87 and 88 are a perspective view and up close perspective view ofthe molded middle sheet of FIG. 84 from below;

FIGS. 89 and 90 are a perspective view and up close perspective view ofa molded middle sheet with blocks extending in two directions;

FIG. 91 is a close up sectional view of the molded middle sheet of FIG.89;

FIG. 92 is a perspective view the molded middle sheet of FIG. 89 frombelow;

FIG. 93 is a close up sectional view of the two mirror molded sheets;

FIGS. 94-97 are perspective views of a single plenum panel in multiplestages of assembly;

FIG. 98 is a close up perspective view of a wire frame pyramid shapedinsert embedded into a glob; and

FIG. 99 is a close up perspective view of a solid pyramid shaped insertembedded into a glob.

DETAILED DESCRIPTION OF THE DRAWINGS

As seen in FIGS. 1 and 2, the panel 2 is comprised of a first sheet 4and a second sheet 6 fixedly mated together via spacing structuralelements 8. In one embodiment the spacing structural elements 8 arecomprised of a first layer 10 and a second layer 12 of rectangularshaped elongated members 14, spaced apart from each other apredetermined spacing distance 16. The arrangement of elongated members14 in the first layer 10 is perpendicular to the arrangement ofelongated members 14 in the second layer 12, forming a matrix 17 ofelongated members 14.

As shown in FIG. 1, a first horizontal edge 18 and a second horizontaledge 20 of the first sheet 4 substantially align with a first horizontaledge 22 and a second horizontal edge 24 of the second sheet 6,respectfully. Similarly, a first vertical edge 26 and a second verticaledge 28 of the first sheet substantially align with a first verticaledge 30 and a second vertical edge 32 of the second sheet 6,respectfully. For sake of clarity, the second sheet 6, though presenteach embodiment depicted, is not shown in FIGS. 2, 3 and 6-10 below.

As shown in FIG. 3, the first 10 and the second layer 12 of elongatedmembers 14 are indented a certain first distance 34 inward from thefirst horizontal edges 18, 22 of the first and the second sheet 4, 6.The first 10 and the second layer 12 of elongated members 14correspondingly overlap the second horizontal edges 20, 24 of the firstand the second sheet 4, 6 by the same first distance 34, creating firstprotruding segments 35. Similarly, the first 10 and the second layer 12of elongated members 14 are indented a certain second distance 36 inwardfrom the first vertical edges 26, 30 of the first and the second sheet4, 6. Likewise, the first 10 and the second layer 12 of elongatedmembers 14 correspondingly overlap the second vertical edges 28, 32 ofthe first and the second sheet 4, 6 by the same second distance 36,creating second protruding segments 37.

These matching indents and overlaps aid in fittingly mating a firstpanel 2 to a neighboring second panel 2 in a secure “tongue in grove”fashion. By providing corresponding indent and overlap on all fouredges, a surface formed of multiple panels may be assembled faster, haveincreased strength and rigidity as a unit, and helps ensure a continuedsmooth panel surface. As in the embodiment shown, the first distance 34of indent and overlap with respect to the horizontal edges can be of thesame value as the second distance 36 of indent and overlap in thehorizontal direction. It is to be noted that the indent and overlap havebeen exaggerated in FIG. 3, to show detail.

As shown in FIG. 4, a portion of the first protruding segments 35 thatoverlap the second horizontal edges 20, 24 of the first and the secondsheet 4, 6, have a chamfered edge 38. These chamfered edges facilitateinserting the first protruding segments 35 of the first 10 and thesecond layer 12 of a first panel 2 into a second adjacent panel 2, andspecifically into a space provided by the inward indent of the elongatedmembers 14 the first distance 34 from first horizontal edges 18, 22 ofthe first 10 and the second layer 12 of the adjacent panel. The chamferon the chamfered edge 38 would terminate between ⅛″ and ⅜″ from thesecond horizontal edges 20, 24 of the first and the second sheet 4, 6,and preferably would terminate approximately ¼″ from the secondhorizontal edges 20, 24 of the first and the second sheet 4, 6.

In a like manner a portion of the second protruding segments 37 thatoverlap the second vertical edges 28, 32 of the first and the secondsheet 4, 6, have a chamfered edge 38 (not shown). These chamfered edgessimilarly facilitate inserting the second protruding segments 37 of thefirst 10 and the second layer 12 of a first panel 2 into a secondadjacent panel 2, and specifically into the space provided by the inwardindent of the elongated members 14 the second distance 36 from the firstvertical edges 26, 30 of the first 10 and the second layer 12 of theadjacent panel. The chamfer on the chamfered edge 38 would terminatebetween ⅛″ and ⅜″ from the second vertical edges 28, 32 of the first andthe second sheet 4, 6, and preferably would terminate approximately ¼″from the second vertical edges 28, 32 of the first and the second sheet4, 6.

As shown in FIG. 5, the panel 2 may be mounted onto mounting elements 40such as roofing rafters or trusses, flooring joists, or wall studs, justas normal plywood or OSB board would be mounted—twelve inches on center.Because of the panels' increased strength, they may be mounted tomounting elements 40 spaced father apart than a plywood or OSB board ofthe same thickness as the sum of the thickness of the first and secondsheet of the panel would require under similar conditions—includingallowing the panels to be mounted on mounting elements 40 spacedsixteen, twenty four, thirty six, forty two, forty eight, and ninety sixinches apart on center.

Turning to FIG. 6, a plurality of plywood veneer strips 42 may alsofunction as the elongated members 14. In such an embodiment, eachelongated structural element 14 may be made up of a plurality of plywoodveneer strips 42, ranging from two to ten ⅛ inch plywood veneer strips42 per elongated structural element 14, and preferably six ⅛ inchplywood veneer strips 42 per elongated structural element 14.

As shown in FIG. 7, the matrix 17 of elongated members 14 may bearranged diagonally with respect to the horizontal 18, 20, 22, 24 andvertical 26, 28, 30, 32 edges of the first and the second sheet 4, 6. Inthis embodiment, the elongated members 14 of the first layer 10 may bearranged at an angle of between 30° and 60° with respect to the firsthorizontal edge 18 of the first sheet 4, and preferably at an angle of45° with respect to the first horizontal edge 18 of the first sheet 4.The elongated members 14 of the second layer 12 may also be arranged atan angle of between 30° and 60° with respect to the first horizontaledge 18 of the first sheet 4, and preferably at an angle of 45° withrespect to the first horizontal edge 18 of the first sheet 4.

As shown in FIGS. 8 through 10, the spacing structural elements 8 mayalso be comprised of blocks 44 being preferably rectangular 46, circular48, or square 50 in shape. Though according to tests, panels 2 utilizingblocks 44 as the spacing structural elements 8 increased the strength ofa comparable plywood board by only half as much as panels 2 utilizingelongated members 14 as the spacing structural elements 8, panelsutilizing blocks 44 as the spacing structural elements 8 offer anincreased assortment of paths that a pipe, tube, wire, or other insert52 may be run through the panel 2, especially if the insert hasdimensions approaching one half the spacing between the first and secondsheet 4,6.

As shown in FIGS. 8 and 9 the blocks 44 would also preferably beindented a first and second distance 34, 36, and similarly have firstand second protruding segments 35, 37, correspondingly overlapping theirrespective edges the same first and second distances 34, 36.

As shown in FIG. 8, the blocks 44 could also be aligned diagonally withrespect to the horizontal 18, 20, 22, 24 and vertical 26, 28, 30, 32edges of the first and the second sheet 4, 6. In this embodiment, theblocks 44 may be arranged at an angle of between 30° and 60° withrespect to the first horizontal edge 18 of the first sheet 4, andpreferably at an angle of 45° with respect to the first horizontal edge18 of the first sheet 4.

As shown in FIG. 11, the protruding segments 35, 37 of the blocks 44would similarly be provided with a chamfered edge 38, to assist ininserting the protruding segments 35, 37 of the blocks of a first panel2 into the space provided by the blocks 44 of an adjacent second panel 2indented at least as much as the distance the protruding segments 35, 37protrude past the edge of the first and the second sheet 4, 6.

Turning to FIG. 12, a perforated panel 2′ with a perforated first sheet4′ is shown. The perforations 46 are arranged in a matrix typearrangement and facilitate the passage of air from the outside of theperforated panel 2′, through the perforated first sheet 4′, via theplurality of perforations 46 into the interior of the perforated panel2′. The perforations 46 are through holes of between 1/16 inches and 1½inches in diameter, and preferably between ¼ inches and 1 inch indiameter, and most preferably between ⅜ inches and ⅝ inches in diameter.The matrix arrangement may be staggered, with each hole spaced between 4and 12 diameters from adjacent holes. Additionally, a layer of screening80 (not shown) may be attached to the inner surface of the perforatedfirst sheet 4′. The perforated panel 2′ is constructed in a similarmanner to the non-perforated panel 2, with the exception of perforatingor using a perforated first sheet 4′, and the perforated panel 2′ may beused in the same manner as the non-perforated panel 2.

Turning to FIGS. 13A and 13B, two panel roofing arrangements are shown.FIG. 13A shows a panel arrangement suited for unfinished attics andnon-living spaces. The panels 2, 2′ are arranged so that neither thefirst nor the second sheets 4, 4′, 6 of the panels 2, 2′ opposite theridge meet, leaving an interior ridge gap 48 and an exterior ridge gap.The ridge will be capped with a ridge vent 52. The bottommost terminaledges 56 of the panels 2, 2′ will be include a screen 54, insect block58, or other permeable occlusion, arranged to allow air passage into theinterior of the panels 2, 2′, but hinder insect entry.

FIG. 13B shows a panel arrangement suited for finished attics and livingspaces. The panels 2, 2′ are arranged so that the first sheets 4, 4′ ofthe panels 2, 2′ opposite the ridge meet, forming a solid interior ridge50, but the second sheets 6 of the panels 2, 2′ opposite the ridge meetdo not meet, leaving an exterior ridge gap. The ridge will be cappedwith a ridge vent 52, and the bottommost terminal edges 56 of the panels2, 2′ will be likewise permeably occluded.

As shown in FIG. 14, a panel arrangement for an unoccupied attic isdemonstrated. Panels 2, 2′ are arranged on trusses and rafters 60 so asto leave an interior ridge gap 48 and an exterior ridge gap, asdescribed in FIG. 13A. The ridge is capped by a ridge vent 52. Warm,moist air 62 from the interior of the house is exhausted through theridge vent, via the interior ridge gap 48 and exterior ridge gap. Thepanels are installed with the permeably occluded 54, 58 terminal edges56 adjacent to openings in soffits or lower fascia (not shown). Coolerair 64 enters through the permeably occluded 54, 58 terminal edges 56,travels through the interior of the panels 2, 2′, absorbing heat fromthe first and the second sheets 4, 4′, 6 and mixing with warm moist airentering through perforations 46, and exits through the ridge vent 52,via the exterior ridge gap.

As shown in FIG. 15A, a panel arrangement for an occupied attic ordirectly roofed living space is demonstrated. Panels 2, 2′ are arrangedon trusses and rafters 60 so as to leave an only an exterior ridge gap,as described in FIG. 13B. The ridge is capped by a ridge vent 52. Warm,moist air 62 progresses from the interior of the house throughinsulation 65 and transfers its heat and moisture to the insulation 65and first sheets 4, 4′ of the panels 2, 2′. The panels are installedwith the permeably occluded 54, 58 terminal edges 56 adjacent toopenings in soffits or lower fascia (not shown). Cooler air 64 entersthrough the permeably occluded 54, 58 terminal edges 56, travels throughthe interior of the panels 2, 2′, absorbing heat from the first and thesecond sheets 4, 4′, 6 and exits warm air 62 through the ridge vent 52,via the exterior ridge gap. The upper terminal edges 56 forming theupper ridge gaps in each embodiment may also be permeably occluded 54,58.

As shown in FIG. 15B a panel arrangement for an unoccupied attic space,using perforated panels is demonstrated. The perforated panels 2′ arearranged such that the perforated first sheet faces the interior of thebuilding, allowing warm air 62 to directly enter into the interior ofthe panel matrix through the perforations 46, from multiple locations inthe attic space. Because of the increased ventilation due to theperforations 46 in the perforated panels 2′, the panels may be arrangedeither with or without an interior ridge gap 48. It is envisioned that aridge vent 52 will be used to cap an exterior ridge gap (not shown) toallow the exhaust of warm air 64 out of the panel matrix, and incombination may be used with one or more gabled vents (not shown).

As shown in FIGS. 16 and 17, the perforated panels 2′ and non-perforatedpanels 2 may be used in conjunction in a roofing constructionarrangement. In one embodiment, the perforated panels 2′ are arranged inthe top one or more rows of the roof sheathing and the non-perforatedpanels 2 are arranged in the bottom one or more rows of roof sheathing.The inner first sheets 4′ of the upper rows of panels 2′ normally lackabutting insulation 65, allowing warm moist air to more freely enterperforations 46. The inner first sheets 4 of the lower rows of panels 2normally have abutting insulation 65, diminishing air transfer ratesthrough perforations 46, and therefore would normally havenon-perforated first sheets 4. It is to be appreciated that sheetingarrangements of all perforated panels 2′, all non-perforated panels 2,or any combination of perforated and non-perforated panels 2′ 2, wouldstill fall in the scope of this invention.

Turning now to FIGS. 18 and 19, the panels may be likewise used in wallsheathing and flooring. As shown in FIG. 18, a panel 2, 2′ may beattached to a wall joist/wall stud 66 and floor joist 68, in a similarmanner as traditional sheeting materials. As with roofing embodiments,the terminal edges 56 will include permeable occlusions 54, 58. In oneembodiment, a terminal gap 74, facilitated by joist spacing elements 72,here proximate to the ceiling joists 70, provides a passageway for airto inter and exit the interior of the panels 2, 2′.

In the embodiment shown in FIG. 19, a panel 2, 2′ is attached to aninsulated 65 wall joist/wall stud and a floor joist 68, with siding 76attached to the exterior sheet of the panels 2, 2′. The flooring panel2, 2′ contains a layer of screening 80 between the first layer 10 andthe second layer 12 of elongated members 14. Cool air 64 enters thepanel 2, 2′ interior by passing through a lower terminal gap 74,facilitated by joist spacing elements 72, then through the permeablyoccluded 54, 58 lower terminal edge 56, moves up through the interior ofthe panel 2, 2′ absorbing heat and moisture from the first and thesecond sheets 4, 4′, 6, and exits warm air 62 through the permeablyoccluded 54, 58 upper terminal edge 56, and out an upper terminal gap74. The air flow may be channeled by one or more first channelingcomponent 78, and as shown in FIG. 20, one or more second channelingcomponents 82. The first and the second channeling components may bedecorative as well as functional, and serve additionally as housingtrim.

FIG. 20 shows a close up of the upper section of FIG. 19, indicated asportion A, showing in detail the upper terminal gap, and the first andthe second channeling components 78, 82.

Turning to FIGS. 21 and 22. A first sheet 4A of a panel 2A withintegrated spacing structural elements 8A is shown. The spacingstructural elements 8A may take the form of, for example, integratedblocks 44A (not shown) or integrated elongated members 14A. In panels 2Aemploying integrated elongated members 14A, the integrated elongatedmembers 14A generally run horizontally on a first sheet 4A and willgenerally run vertically on a second sheet 6A.

Turning to FIGS. 23, 24, and 26A-D, the profiles of the integratedelongated members are generally either rectangular 100, square 101, orcurved 102, or some combination of each, depending upon the applicationrequirements, each providing a plurality of parallel, unobstructed,contiguous pathways 5. As shown in FIG. 26, for example, the integratedelongated members may have flat tops 104, flat sides 106, and anglededges 108, and/or curved tops 110, curved sides 112, and rounded edges114 or chamfered edges 116. Additionally the sides maybe perpendicularwhere they intersect the top and/or the interior surface of the sheet4A, 6A, or at a non-perpendicular angle.

As shown in FIG. 25, similar to panels 2′ described above, a first sheet4A′ and/or second sheet 6A′ of panels 2A′ with integrated elongatedmembers 14A may also possess perforations 46A, and may be used insimilar embodiments as those described in paragraphs above.

Turning to FIG. 27, a panel 2A comprised of a first and a second sheet4A, 6A, each having integrated elongated members 14A. In thisembodiment, the integrated members 14A on the first sheet 4A arearranged parallel to the integrated members 14A on the second sheet 6A.This arrangement allows the integrated members 14A on the first sheet 4Ato be nested within the spacing distance 16 separating the integratedmembers 14A on the second sheet 6A from one another, when the first andthe second sheet 4A, 6A are brought together to form the panel 2A. Inthe same way, this allows the integrated members 14A on the second sheet6A to be nested within the spacing distance 16 separating the integratedmembers 14A on the first sheet 4A from one another. The integratedmembers 14 A on the first sheet 4A would attach directly to the interiorsurface of the second sheet 6A in this embodiment. The parallelunobstructed continuous pathways 5 for air would be defined by theinterior surface of the first and second sheets 4A, 6A and theirrespective integrated members 14A, similar to a other single layerembodiments, as compared to being defined by the interior surface of oneof the first sheet and second sheet 4A, 6A, and at least three separateelongated members 14, 14A, as in multiple layer embodiments.

In a related embodiment, integrated elongated members 14A of a first andsecond sheet 4A, 6A could be arranged parallel such that, instead ofnesting within respective spacing distances 16 in the posing sheets 4A,6A, as shown in FIG. 27, the parallel elongated members 14A of eachsheet 4A, 6A could stack substantially directly on top of one anotheralong the full length of the elongated members 14 A (not shown). Thiswould create parallel unobstructed continuous pathways 5 for air thatwould be two elongated members 14A high, and defined by for elongatedmembers 14A, two from each of the first and the second sheet 4A, 6A, andthe interior surface of both the first sheet 4A and the second sheet,6A.

Turning to FIG. 28, a panel 2 is shown wherein the respective elongatedmembers 14 of the first and the second sheets 4A, 6A interacts with oneanother at their point of attachment in a notch/recess fashion. At thepoint where a first elongated member 14 contacts a second elongatedmember 14, one or both of the first and the second elongated member 14is provided with a notch 118. In the case where only one of the firstnor the second elongated member is provided with a notch 118 at theirpoint of interaction, this allows either the first or second elongatedmember 14 to recess into the notch 118 on the opposed elongated member14. Or, in the case that both the first and second elongated members 14are provided with opposing notches 118 at the point of interaction, thisallows each elongated member to recess into the notches 118 provided onthe opposed elongated member 14. While this notch/recess arrangementcreates a potentially stronger bond amongst the elongated members 14 andtherefore the panel 2 as a whole, at the same time this decreases thesize of the parallel, contiguous, unobstructed pathways 5 for air withinthe panel 2.

Additional embodiments of the elongated matrix members 14 areenvisioned. In their simplest form, an elongated matrix member 14 is astick or extrusion with a square or rectangular cross section and alength equal to a parallel axis of the sheet 4, 6 to which it isattached. The elongated matrix members 14 are ideally ¾″×¾″ in crosssection, but, as mentioned above, can be larger (2″ or greater) orsmaller (¼″ or smaller) as required for the application. The elongatedmatrix members 14 are preferably attached to at least one sheet 4, 6 andto one another where multiple layers of elongated matrix members 14intersect, in order to transfer shear stresses, though the elongatedmatrix members 14 may have one or more locations where they intersectthat they are not attached, in order to increase flexibility of theoverall panel, as may be required in certain situations.

Additionally, engineered matrix members 120 can be utilized andmanufactured from a variety of materials, like organic, wood, celluloseor other fibrous materials, plastics, metals or other materials that canbe shaped or extruded, and can be formed into the square or rectangularcross sectional shapes discussed previously, or formed into one of manyspecialized shapes.

Specialized shaped engineered matrix members 120 will preferably have afirst flat section 122 with a rectangular outer face, an opposed secondflat section 124 with a rectangular outer face, and transverse section126 connecting an inner face of the first flat section 122 to an innerface of the second flat section 124. The outer face of at least one ofthe first and the second flat section 122, 124 will preferably beattached to at least one of a sheet 4, 6 and an outer face of a first ora second flat section 122,124 of an additional specialized shapedengineered matrix member 120 disposed in an adjacent layer. The range ofshapes and structures of the specialized shaped engineered matrixmembers 120 will vary mainly based upon the design of the transversesection 126.

In a first embodiment of specialized shaped engineered matrix members120, “I” beam shaped members 125 are formed by the first and second flatsections 122, 124 of engineered matrix members 120 being joined by arelatively thin and elongate transverse section 126. The thin elongatetransverse section 126 and the inner faces of the first and the secondflat sections 122, 124 define two narrow channels, one on each side ofthe thin elongate transverse section. These narrow channels act toincrease the size of parallel, contiguous, unobstructed pathways 5 forair to pass between two adjacent “I” beam shaped members 125 of a commonlayer, as compared to similarly spaced elongated members 14 with asquare or rectangular cross section.

Additionally, the thin elongate transverse sections 126 in the “I” beamshaped members 125 may be solid or perforated. The perforated “I” beamshaped members 125 offer the benefit of enhanced cross ventilationperformance and increase the interior cabling options of the panels, asthe perforations 128 provide additional pathways 129 for air and/orcables to pass through the panel 2, and through the very “I” beam shapedmembers 125. Either perforated or solid, the “I” beam shaped members 125offer the benefit of being easily extruded and utilized in a panel 2.

Turning to FIG. 30, in a second embodiment of specialized shapedengineered matrix members 120, “truss” shaped members 130 areconstructed by the first and second flat sections 122, 124 of engineeredmatrix members 120 being joined by a truss web 132 transverse section126. The truss web 132 is formed of a plurality of truss web supports134 that can be both diagonal supports of the same or varying angles,and vertical supports. The truss web supports 134 will normally be ofapproximately an equal width as that of the first and the second flatsections 122, 124.

In a first embodiment of truss shaped members 130, the truss web 126 iscomprised of a plurality of diagonal truss web supports 134 that form acontinuous series of triangles down the length of the truss shapedmember 130. That is, except for terminal ends of the truss shapedmembers, at each intersection of a diagonal truss web support 134 withthe inner face of the first and the second flat sections 122, 124,another diagonal truss will also intersect the same inner face of thefirst and the second flat sections 122, 124 at an adjacent location.Such adjacent intersections form a triangulated parallel chord truss.The truss web supports 134 can be comprised of folded or formedmaterial, and similar to the perforated “I” beam shaped members 125, thetruss shaped members 130 to facilitate additional airflow and additionalpathways for running cables and pipes through the panels 2, especiallywith the additional pathways diagonally and orthogonally through thespecialized shaped engineered matrix members 120.

Turning to FIG. 31, in a second embodiment of truss shaped members 130,the intersection of the diagonal truss web supports 134 with the innerface of the first and the second flat sections 122, 124 can be spacedeither a fixed or varying distance from one another. These “skip truss”shaped members 136 are similar to the truss shaped members 130, butbecause they have less truss web supports 134, they are less costly tomanufacture and fabricate and offer increased size and angles ofpathways through the panels 2 and the specialized shaped engineeredmatrix members 120, while still retaining much of the superior strengthqualities of the truss shaped members 130.

Turning to FIG. 32, in a third embodiment of specialized shapedengineered matrix members 120, honeycomb shaped members 138 areconstructed by the first and second flat sections 122, 124 of engineeredmatrix members 120 being joined by a honeycomb web 140 transversesection 126. The honeycomb web 140 is formed by a plurality of honeycombor other repeating open geometric shapes connected to one another, andarranged such that an axis of opening B-B is disposed perpendicular to along axis A-A. Similar to the perforated “I” beam shaped members 125 andthe truss shaped members 130, the honeycomb web 140 of the honeycombshaped members 138 facilitates additional air flow and additionalpathways 129 for running cables and pipes through the panels 2,especially with the additional pathways diagonally and orthogonallythrough the specialized shaped engineered matrix members 120.

Turning to FIG. 33, in a fourth embodiment of specialized shapedengineered matrix members 120, corrugated shaped members 142 areconstructed by the first and second flat sections 122, 124 of engineeredmatrix members 120 being joined by a corrugated or sinusoidal typecurved web 144 transverse section 126. The peaks and the troughs of thecorrugated web 144 attach to the inner faces of the first and secondflat sections 122, and curving a path in-between. The curved shape ofthe corrugated web 144 provides a different profile and potentiallywider pathways 129 for air flow and running cables, as compared to thetruss shaped members 130.

The specialized shaped engineered matrix members 120 may be used in allsituations as the rectangular shaped elongate members 14. Thespecialized shaped engineered matrix members 120 may be formed in aseparate process and later attached to the sheets 4, 6, or, similar tothe integrated elongated members 14A, the specialized shaped engineeredmatrix members 120 may be formed, in whole or part, together with thesheets 4A, 6A. Panels 2 may be constructed out of all non-engineeredspacing structural elements 8, all engineered matrix members 120, orsome combination of each.

Turning now to FIGS. 34-37 a further additional embodiment of theinvention disclosed herein is disclosed. As can be seen, in thismulti-plenum panel 202 embodiment an additional top third sheet 204,parallel in plane with both the first (now middle) sheet 206, and thesecond (now bottom) sheet 208, has been affixed to the now multi-plenumpanel 202 with blocks 210, to create two separate plenums—a upper plenum212 and a lower plenum 214. The plenums 212, 214 extend from onemulti-plenum panel 202 to adjacent multi-plenum panels 202 such that thetop and the lower plenums 212, 214 can extend the length and width of anentire floor of a building. The three sheets 204, 206, 208 are ideallyjoined by regularly spaced blocks 210, which provide excellent strengthcharacteristics and superior clearance between the top and middle sheets204, 206 and between the middle and bottom sheets 206, 208, facilitatingair flow and running pipes or wires as needed.

The multi-plenum panel 202 is preferably composed of three sheets ofplywood or OSB preferably in the standard size of 4×8 foot sheets. Thesheets are nominally ¼ inch thickness. The sheets are spaced from, andjoined to one another by blocks 210, preferably made of standard framinglumber of 2×4 inch nominal size (3.5 inch×3.5 inch×1⅝ inch), because ofthe high strength to weight ratio of wood, combined with its relativehigh availability and low cost. The blocks 210 are preferably spaced 7inches on center each way. The blocks 210 are fastened with adhesiveand/or mechanical means to enable the essential shear transfer to themiddle sheet 206. The blocks 210 of the lower plenum 214 are preferablyvertically aligned with the blocks 210 of the upper plenum 212, to allowfor better transfer of stress. The size and spacing of the blocks 210may be changed, but should ideally provide for at least threeunobstructed air pathways 216 per every 24 linear inches along the edgeof the multi-plenum panels 202 in each plenum. That is, both threepathways 216 in the upper plenum 212 and three pathways 216 in the lowerplenum 214 per every 24 linear inches of the multi-plenum panel 202.Additionally, as shown in FIG. 35, there is ideally a pathway 216between each row of bocks 210, along both the long and short edges ofthe multi-plenum panel 202. In FIG. 35, there are at least ten pathways216 between the two long edges and at least five longer pathways 216between the two short edges per each plenum 212, 214. Each unobstructedpathway 216 should ideally measure between 5 and 6 square inches, andpreferably be over 5.5 square inches in size, and should extendcontinuously from one edge of a multi-plenum panel 202 to another,opposite edge of a multi-plenum panel 202. It is anticipated that onlyplenum taps 218, registers 220, and plenum tubes 222 (each describedfully below) will substantially impede these unobstructed pathways 216.These pathways 216 will allow for the easy passage of supply and returnair, and facilitate easy placement of wire, cables, and pipes throughthe multi-plenum panels 202, without substantially impeding the passageof air.

The multi-plenum panel 202 allows for large spans for flooringapplications of 48 inches with minimal deflection even when using ¼ inchsheets 204, 206, 208. Ideally, the top sheet 204 may be thicker (⅜ inchor ½ inch). The structural mechanism is that the middle sheet 206facilitates the necessary shear transfer for the multi-plenum panel 202to act as an “I” beam with significant strength and stiffness.

Ideally, the blocks 210 are a 1⅝ inch thick, which is the commonthickness of finished structural lumber typically used in the buildingtrades; however, the thickness could be larger or smaller depending onspan requirements and air distribution requirements.

As shown in FIG. 38, the blocks 210 may be inset preferably 1⅝ inchesfrom the edge. In such an arrangement, a strip 224 of 1⅝ inches×1⅝inches by either 48 inches or 96 inches to be inserted along the edgefor bearing strength. Additionally, foam sealant 226 of closed or opencell material could be applied along one or all edges either at thefactory or in the field. This is primarily for edges of multi-plenumpanels 202 that will form the boundary of the plenums, that is, theedges that are not joined to other multi-plenum panels 202. The sealant226 helps prevent supply air from leaking from the plenums to unintendedsurrounding space. Additionally, the edge of the multi-plenum panels 202may be sealed with impenetrable and/or airtight tape (not shown).

Where two adjacent multi-plenum panels 202 are joined, a maximumunobstructed flow of air between the respective plenums of the adjacentmulti-plenum panels 202 is desired—taking into account structuralsupport requirements. Therefore, a perforated strip may be used on alledges, to both increase bearing strength, but still allow for panel topanel flow of air. Alternatively, blocks 210 may be arranged flush withthe edges, or additional blocks 210 or larger blocks 210 may be used toreach the edges of the sheets, to aid in bearing strength, while stillmaintaining air pathways 216. Additionally, the blocks may extend beyondthe edges of one or more sheets 204, 206, 208, on one or more edges ofthe multi-plenum panels 202, and on a corresponding opposite edge of theone or more sheets 204, 206, 208, the blocks can be recessed from theedge by a similar amount. This will allow the blocks from a firstmulti-plenum panel 202 to matingly fit in a recess space in the plenumof an adjacent second multi-plenum panel 202 to which the firstmulti-plenum panel 202 is to be joined. Additionally, or alternatively,the blocks may be convexly chamfered on one edge of the multi-plenumpanel 202, and the blocks may be concavely indented along an opposingedge of the panel 202—either the convexly chamfered or the concavelyindented blocks or both may extend beyond the edge of the sheets 204,206, 208, and fittingly mate with one another when two multi-plenumpanels 202 are abutted side by side with one another, parallel in plane.

The multi-plenum panels 202 would be installed like regular sheathingusing a combination of adhesive along the joists 228 and preferablyscrews through a series of blocks 210 into the joist 228. But asdiscussed above, because of the dramatically increased strength of themulti-plenum panels 202 verses regular floor sheathing, the joists 228may be spaced at much greater distances from one another, including 48inches on center, or farther.

The locations of the blocks 210 would be marked or otherwise shown onthe exterior of the top and the bottom sheets 204, 208 to facilitateregister 220 placement and plenum taps 218, and otherwise aid ininstallation of the multi-plenum panels 202.

The multi-plenum panels 202 will preferably include necessary plenumtaps 218 in dimensions suitable for commercially available duct coversor registers 220 which are typically in size of 2×10, 2×12, 4×10, 4×12,4×16, and other sizes.

As shown in the cutaway in FIG. 39, tapping into the upper plenum 212only requires cutting a hole suitably sized for the register 220.Tapping into the lower plenums 214, on the other hand, will normallyrequire a lower plenum tap 218, as shown in FIGS. 40-42. The opening inthe top sheet 204 for the lower plenum tap 218 is approximately 1 inchlarger than the opening in the bottom sheet 208. This facilitatescutting the bottom hole and securely attaching the plenum tap 218 toboth sheets 204, 206 with caulking and mechanical means. The lowerplenum tap 218 can be sized to fit standard registers 220.

The plenum taps 218 should be installed with caulk under all flanges andwith screws. Plenum taps 218 can be constructed from either sheet metalor plastic.

As shown in FIG. 43, the plenum taps 218 can be constructed with one ormore selector doors 230 and selector levers 232. If the selector leveris in a first position (as shown), the plenum tap selector doors 230open an air pathway to the lower plenum 214 and close an air pathway tothe upper plenum 212. Conversely, if the selector levers 232 are movedto a second position, the plenum tap selector doors 230 fold down toopen the air pathway to the upper plenum 212 and close the air pathwayto the lower plenum 214. This way, for example, if warm air is suppliedthrough the upper plenum 212 and cold air is supplied through the lowerplenum 214, a given register 220 can function as a supply register 220regardless of whether the upper or lower plenum 212, 214 is supplyingthe air. If the lower plenum 214 supplies cold air, the selector levers232 are moved to the first position, the plenum tap selector doors 230access the lower plenum 214 for air supply and close off the upperplenum 212, to keep air from leaking from the supply (here lower) plenuminto the return (here upper) plenum. Conversely, if the upper plenum 212supplies warm air, the selector levers 232 are moved to the secondposition, the plenum tap selector doors 230 then access the upper plenum212 for air supply and close off the lower plenum 214. The sameprinciple will work for return registers 220 affixed to the plenum taps218 constructed with selector doors 230 and selector levers 232. Oneregister 220 connected to such a plenum tap 218 may be used as a returnregister 220 regardless of which plenum is supplying air, as the plenumfor return air may be selected with the selector lever. This way,dedicated supply registers 220 can be placed near the exterior walls ofthe building and dedicated return registers 220 may be placed moretoward the interior of the building, each accessing the upper or lowerplenums 212, 214 as need be.

This multi-plenum panel flooring/air supply system would provide manyadvantages. For example, the multi-plenum panels 202 allow airdistribution with substantially less or no ductwork. This leads toshorter construction time, cost savings, and decreased spacerequirements. The cost of ductwork for an average sized house can easilybe $6,000 to $10,000, depending on complexity and design. If the savingsare assumed to be $7,000 on an average house this would equate to asavings value potential of $86.15 per multi-plenum panel 202 used forflooring.

Also, the multi-plenum panels 202 easily allow air distribution to anylocation in any room. The multi-plenum panel 202 allows air distributionto smaller spaces that conventionally are not supplied conditioned airdue to the cost relative to room size such as small bathrooms, laundryrooms, walk-in closets, pantries, small dens/studies. Because of thecost effectiveness, the multi-plenum panel 202 can inexpensively deliverconditioned air to and provide a cold/hot air return from every room,including closets. This is something only very elaborate and expensivesystems now provide, because of the high costs providing a complete dualduct system involve.

As an additional benefit, if the upper plenum 212 is used to deliverheated air in the winter, the warmed upper plenum 212 can radiantlycreate and provide a warm floor to every room on a given level. This isa very desirable feature normally only available by using an expensiveliquid radiant heating system.

The same procedure is used for providing cool air distribution in thesummer. However, to prevent cold floors, if they are undesired, the coolsupply could be directed to the lower plenum 214 while the return warmerair to the upper plenum 212.

If the two plenums are un-insulated between one another, the return airtraveling through the return air plenum may be tempered, that is, heatedor cooled, by the supply air in the supply air plenum. This offers thebenefits of a built in air exchanger recapturing heat loss or coolinglosses.

Testing shows deflections in the range of 1/200 for a 150 pound persquare foot load having a 48 inch span. For a load more typical ofresidential design, the multi-plenum panel 202 would expect a deflectionof 1/600 for a 48 inch span—greatly exceeding typical design criteriaand expanding design building possibilities.

Using a 48 inch span for flooring would reduce the number of joists 228required for the flooring by two thirds, saving significant material andlabor costs. These savings could be around $3,000 for a typical house.Additionally, the electrical, mechanical, and plumbing trades would alsobenefit from having two thirds less obstacles (joists 228) to run theirvarious wires, ducts and pipes. Again, savings could be significant tothese trades, and could be around $2,000 for a typical house. Thus,there are significant savings in time, labor, and money that areassociated with utilizing a multi-plenum panel 202 for combined flooringand air supply. Savings of around $12,000 for a typical house areenvisioned, equating to a $127 savings per multi-plenum panel 202, forthe 94 multi-plenum panels 202 in such a house.

The multi-plenum panels 202 can provide for the distribution of airthrough the ceiling of a lower level 234 (e.g., first story) and thefloor of an upper space (e.g., second story), to the air of an upperlevel 236. This means one multi-plenum panel 202 directly connected to acentral heating and/or cooling unit 238 can supply and return air to twostories or levels at once. For such a design, flooring multi-plenumpanels 202 used to support a second story 236 would use longer plenumtaps 218 to access air distribution from a first story 234 for thesecond story 236. That is, to reach and be flush with the first storyceiling, directly below the second story flooring multi-plenum panels202, longer plenum taps 218 would be required to accommodate theinter-story joist 228 thickness. Such first story 234 to second story236 plenum taps 218 would allow direct condition air suppliedmulti-plenum panels 202 under the first story 234 to supply conditionedand return air a two story building.

Turning now to FIG. 44, an air distribution system using multi-plenumpanels 202 as described is shown. In the example shown, in a basement orlowest level 240 of a building a central heater/air conditioner 238supplies heated air through a supply trunk 242 to an upper plenum 212 ofthe multi-plenum panels 202 of a first story 234. The forced heated airspreads out across the upper plenum 212, remaining separate from thelower plenum 214, and exits the upper plenum 212 in one of a pluralityof registers 220 tapped into the upper plenum 212 (only one upper plenum212 register 220 is shown). The heated air dissipates through the firststory 234 air space, heating the first story 234 air. The heated aircontinues to rise, passing through a longer second story plenum tap 218and register 220 and into a second story 236 air space. Some of the airwill cool down and pass from the second story 236 air space, through anadditional longer second story 236 plenum tap 218 and back into thefirst story 234 air space. It is also envisioned that the longer secondfloor plenum taps 218 may be electrically wired and narrow fans (notshown) will be placed in the longer second story 236 plenum taps 218 toaid in air circulation. Once cooler air is in the first story 234 airspace, it is then returned via suction or lower air pressure through oneof a plurality of registers 220 tapped into the lower plenum 214 of themulti-plenum panels 202 of the first story 234 (only one lower plenum214 register 220 is shown). A return trunk 244 then brings the coolerreturn air from the lower plenum 214 back to the central heater/airconditioner 238 in the lowest level 240, to be heated, and begin theprocess over again.

In a further example of an air distribution system using multi-plenumpanels 202, as shown in FIG. 45, the central heater/air conditioner 238supplies forced air and receives return air directly from both the firstand second story 234, 236 multi-plenum panels 202. A separate supplytrunk 242 attaches to the upper plenum 212 of the multi-plenum panels202 on each of the first and second stories 234, 236. Similarly, aseparate return trunk 244 attaches to the lower plenum 214 of themulti-plenum panels 202 on each of the first and second stories 234,236. By directly supplying and returning air from each of the twostories 234, 236, the climate of the two stories 234, 236 may becontrolled to a higher specificity, resulting in higher comfort levelsfor building occupants.

Turning now to FIGS. 46 and 47, the connection of the air supply andreturn trunks 242, 244 to the multi-plenum panels 202 will be discussed.As shown, the air supply and return trunks 242, 244 preferably to do notdeliver and receive air from the multi-plenum panels 202 through asingle large opening. Rather, a plurality of smaller, preferablycircular, openings or mating holes 246 are coupled to circular plenumtubes 222 to form the connection between the trunks 242, 244 and therespective plenums 212, 214. In this embodiment, the trunks 242, 244extend to the lower face of the bottom sheet 208. For the return trunk244, a plurality of smaller circular plenum tubes 222 extends from thetrunk 244, through circular mating holes 246 in the bottom sheet 208,and into the lower plenum 214. The return plenum tubes 222 willpreferably each have flanges to be secured to the inside face of thebottom sheet 208. For the supply trunk 242, a similar plurality ofsmaller plenum tubes 222 extends from the trunk 242, through circularmating holes 246 in the bottom sheet 208, and into the lower plenum 214,and continues through the lower plenum 214, through circular mattingholes 246 in the middle sheet 206, and into the upper plenum 212. Thoughthe supply plenum tubes 222 extend through the lower plenum 214, they donot exchange air with the lower plenum 214. Similarly, the supply plenumtubes 222 will preferably have flanges to be secured to the upper faceof the middle sheet 206. The supply plenum tubes 222 may be insulated toprevent heat exchange when crossing the lower plenum 214.

By transitioning between the trunks 242, 244 and the plenums 212, 214via the plurality of smaller openings (mating holes 246), the structuralintegrity of sheets 208, 206 and the multi-plenum panel 202 as a wholeare better maintained. Additionally, by shaping the openings 246 ascircles, the openings 246 avoid high stress/lower strength corners ofregular polygon shapes. The supply and return trunks 242, 244 may bothbe connected to the same multi-plenum panel 202, but preferably areconnected to separate multi-plenum panels 202, to better dissipate thestructural weakness caused by forming the mating holes 246 in thesheets.

Turning to FIG. 48, a single multi-plenum panel 202 is shown supportedby joists 228 spaced 48 inches off center. Preferably, the joists 228will be aligned under the blocks 210, to aid in stress transfer. At theintersection of two multi-plenum panels 202, additional blocks 210,longer blocks 210, or some other insert may be placed in the plenums toaid in stress transfer.

Turning to FIG. 49, a detail of the edge of a lower level or first storymulti-plenum panel 202 is shown. Along the perimeter of the multi-plenumpanel 202, a strip 224 has been inserted to better bear the load of theexterior wall 248 above. The joist 228 below the multi-plenum panel 202is vertically aligned with the strip above the joist 228 and thefoundation wall 250 below.

As seen in FIGS. 50-52, different means may be used to connect adjacentmulti-plenum panels 202 to one another. As the multi-plenum panels 202will be carrying pressurized air in at least one of the two plenums 212,214, it is important to minimize air leakage from the pressurized plenumto the surrounding air space. Further, because, unlike traditionalductwork, the multi-plenum panels 202 serve a primary structural supportfunction also, it is important to transfer stresses at the edge of themulti-plenum panels 202 and provide structural continuity among allmulti-plenum panels 202 joined on a single floor. To assist in reducingair leakage at the intersection of two adjacent multi-plenum panels 202,special shaped sheet edges or joining attachments are used.

FIG. 50 shows a tongue and groove pattern 252 along the edges ofadjacent multi-plenum panels 202. The tongue of a first sheet 204, 206,208 will be inserted into a mating groove of an adjacent sheet 204, 206,208, and provides a continuous connection that transfers stress in bothdirections and minimizes air flow. Adhesive and/or caulking would alsopreferably be applied in the tongue and groove fitting 252, to increasethe strength of the bond and decrease any air losses.

FIG. 51 shows a lap joint 254, where two mating edges are joined. Thismethod may be easier to be used with thinner sheets 204, 206, 208 arejoined together. Adhesive and/or caulk would preferably be applied alongthe joint to help minimize air loss and also increase joint strength inboth directions of vertical stresses.

FIG. 52 shows an elongated “H” clip 256, which could be constructed frommetal or plastics, to connect the sheets 204, 206, 208 of adjacentmulti-plenum panels 202. Adhesive and/or caulk could be used inconjunction with the clips 256. The clips 256 would be attached to theedges of the sheets 204, 206, 208, and are intended to be continuous andeither 48 inches or 96 inches in length. Though the edges shown in thisfigure are rectangular, alternate shaped edges, like those shown inFIGS. 50 and 51, or other non-rectangular edges could be used with clips256 that are shaped to be flush with each connecting edge. Suchalternate clips 256 would, therefore, not necessarily be shaped like the“H” in FIG. 47, but would shaped to mirror whatever non-rectangularedges of the sheets 204, 206, 208 joined. An advantage of using theclips 256 to mate the edges of two sheets 204, 206, 208 together is thatif the clips 256 are formed of high strength material, the clips 256could add additional structural integrity to the naturally potentialweak location of the intersection two multi-plenum panels 202.

With each connection, an impervious and/or airtight adhesive tape can beapplied to joined edges to ensure air tightness. Further, an imperviousand/or adhesive tape can be applied to the entire edge wrapping into themulti-plenum panel 202 at the top and bottom to ensure all the edges areairtight.

A floor multi-plenum panel 202 prototype was tested with the followingresults. Three separate ¼ inch thick 2×4 foot CDX plywood sheets wereused for the top, the middle and the bottom sheets 204, 206, 208 of themulti-plenum panels 202. The matrix used to join the bottom and themiddle sheet 208, 206 and the middle and the top sheet 206, 204respectively were 3½ inch by 3½ inch Pine/Spruce blocks 210, withapproximately 3½ inch spacing between the blocks 210. That is, threeblocks 210 were spaced evenly in 24 inches, and six blocks 210 werespaced evenly in 48 inches. As a result of the bock 210 size andspacing, there was nine square inches of unobstructed free vent area perlinear foot. The blocks 210 were attached to the sheets 204, 206, 208using an interior wood glue type of adhesive—specifically a polyvinylacetate glue.

The multi-plenum panel 202 was loaded with 1,200 lbs. spaced uniformlyacross the multi-plenum panel 202 creating a pressure of 150 pounds persquare foot. The weighted multi-plenum panel 202 was supported along theshort two foot edges creating a 48 inch simple span, with 44 inchesclear between the supports. The multi-plenum panel 202 had a maximumdeflection of 0.250 inches, an “

l” of 192 and an area moment of inertia, I_(x), in⁴ per foot, equal to20.00.

A control panel was used for comparison. The control panel was a single½ inch sheet of plywood measuring two feet by four feet. The controlpanel was loaded with 600 lbs. spaced uniformly across the sheet,creating a pressure of 75 pounds per square foot. The control panel wassimilarly supported along its shorter two foot edge, creating a 48 inchsimple span, with 44 inches clear between the supports. The controlpanel displayed over an inch of deflection, with only half the load ofthe floor panel. In more detail, the control panel had a maximumdeflection of 01.10 inches, an “

l” of 44 and an area moment of inertia, I_(x), in⁴ per foot, equal to0.016.

Thus, the multi-plenum panel 202 demonstrated a bending strength of 9times greater than the equivalent thickness of plywood alone. Themulti-plenum panel 202 demonstrated a significant strength at a 48 inchspacing and would be serviceable for residential and commercial uses atthis span with only ¼ inch sheets 204, 206, 208. These results were abetter than predicted strength, despite using an inferior polyvinylacetate adhesive instead of using a preferable thermosetphenol-formaldehyde adhesive between the blocks 210 and the sheets 204,206, 208.

Alternate embodiments of the multi-plenum panel are envisioned. Theinvention consists of three sheets 204, 206, 208 of the same size andassembled in parallel planes separated ideally by blocks 210 of wood ina square shape, but the blocks 210 could also be rectangular, round orthe sheets 204, 206, 208 could also be separated by a matrix ofelongated wood members, or an extruded or engineered matrix, in astacked perpendicular matrix or otherwise arranged as described in theabove embodiments of the ventilated structural panels 2, 2′, 2A. Theinterior could also be an arrangement of plastic or metal extruded orformed members as described above. Additionally, a single plenum panelembodiment, with two sheets connected by a plurality of structuralspacing elements, as described above, may be connected in an air tightmanner to a central heater and air conditioner 238 to one of deliverconditioned air to or receive return air from an entire level of abuilding, or some part thereof.

The sheets 204, 206, 208 can be of various thicknesses. The top sheet204 could be 1/4 inch to ½ inch to even ⅝ inch, ¾ inch or 1 inch toaccommodate floor covering and structural needs. The middle sheet 206only needs to be ¼ inch in thickness to accomplish the structural needsof a 48 inch span. The bottom sheet 208 also needs to only be ¼ inchthick to accomplish the structural needs for a 48 inch span, but eachsheet 204, 206, 208 may have the various thickness options listed for ofthe top sheet 204, as the specific designs may required. Also, thesheets 204, 206, 208 can be of different thicknesses to accommodatedifferent needs. The sheets 204, 206, 208 are ideally 4′×8′ sheets, asthis size is typically used in the building trade, but the sheets 204,206, 208 can be sized larger or smaller.

The sheets 204, 206, 208 are ideally constructed of plywood or OSB, butcould also be of a plastic, vinyl, metal or other man made or naturalmaterial.

The sheets 204, 206, 208 may be treated with an antibacterial agent oreven with a waterproofing to prevent the formation of mold should themulti-plenum panels 202 be used for cooling and where condensation is arisk due to cool supply air and high humidity environments.Additionally, the interior of the multi-plenum panels 202 could beentirely coated with a waterproofing covering.

The multi-plenum panels 202 and blocks 210 could also be constructed outof pressure treated lumber and plywood to inhibit any decay or possiblemold. An alternative solution is to provide supply air at a temperaturewhere condensation is not in the probable range of the design.Alternatively, if condensation is possible, then the system could beprogrammed to air dry the plenums 212, 214 sufficiently after achievingdesired room ambient temperatures.

Additionally, the sheets 204, 206, 208 could be coated to preventcondensation absorption if it occurs, and could be insulated with a“blanket” of thin reflective insulation on the inside and/or outsidefaces of each sheet 204, 206, 208.

Turning now to FIG. 53, the various structural spacing elements for thesingle and multi-plenum panels 2, 202 will be further described.

Turning to FIG. 53, various embodiments of the spacing structuralelements 8 are further described. The spacing structural elements 8 canalso be constructed by extruding or depositing a predetermined amount ofadhesive or plastic or foam in a regular geometrical pattern orspecialized pattern for structural purposes. These deposits or globs 258would be a deposit of semi-liquid material with adhesive and structuralqualities when cured. The material may cure with or without heat,and/or, for example, with exposure to oxygen or various wavelengths ofelectromagnetic radiation. Once cured, the glob 258 can have the samequalities of the block 210 spacing structural elements 8 above, withsimilar orthogonal intersecting air flow paths, spacing between, heightand width measurement, and other qualities.

The anticipated process utilizing the globs 258 is to deposit therequired amounts of semi-solid/semi-liquid material in a predeterminedpattern, as required for structural needs, on the bottom sheet 6, 208 ofthe panel 2, 202. The top sheet 4, 204 (or middle sheet 206 for amulti-plenum panel 202) is then laid on the bottom sheet 208 andcompressed to the desired thickness causing some lateral expansion inthe globs 258, such that they attain a circular shape of preferablybetween 2″ to 8″, as required for structural needs. The quantity ofmaterial in each glob 258 is preferably between 1.5 cubic in. and 50cubic in., not including consideration of the displacement of volumefrom any imbedded insert 260 (see FIG. 55).

As shown in FIG. 53, for multi-plenum panels 202, the deposits or globs258 are also made to the top surface of the middle sheet 206 and the topsheet 204 is then placed on the middle sheet 206 and compressed to thedesired thickness.

The glob 258 material is semi-liquid/semi-solid adhesive or foam orsimilar material. The glob 258 may have a flat-bottomed teardrop or“Hershey's kiss” shape after being deposited and before compression. Theglob 258 material preferably has a viscosity and quantity such that whenthe sheets 204, 206, 208 are pressed together the resulting thickness ofthe assembly is of the desired panel 2, 202 thickness. Spacers 262and/or inserts 260, described below, may be used to insure properspacing when the sheets 204, 206, 208 are pressed together. Spacers 262can be placed around the perimeter and interior between the adhesivedeposits to insure the desired thickness when pressed. The spacers 262can be permanently attached to one or both sheets 204, 206, 208 or justbe temporarily placed, to be later removed. The spacers 262 can bepositioned on the sheets 204, 206, 208 before, during, or after theglobs are desposited.

The spacers 262 can consist of pressed metal shapes that penetrate onesheet 204, 206, 208 when pressed, and/or could have one or moreprotrusions or spikes 264 that penetrates the adjacent sheet 204, 206,208 when the other sheet 204, 206, 208 is pressed into the panel 2, 202assembly (see FIG. 56). The spacers 262 can also be blocks 210 of woodor plastic that can be adhered to one or both of the adjacent sheets204, 206, 208. Spacers 262 can also consist of plastic shapes spaced orglued to one sheet. The spacers 262 can be also be free from adhesive,or only have non-permanent adhesive, and be designed to be removed afterthe globs 258 cure.

Referring to FIG. 55, a first example of an insert 260 is shown. A ballor sphere of diameter between ½″ and 3″ is embedded in a quantity ofadhesive and/or foam glob 258. The insert 260 and the glob 258 may bedispensed or extruded at the same time through a common dispenser orextruder, or they may be dispensed via separate dispensers at the sameor different times. The insert 260 may be solid or hollow, and may havea continuous surface as shown, a perforated surface, or a cage surface,as shown in FIG. 57. The surface of the insert 260 may be smooth, asshown in FIG. 55, textured, or, FIG. 57, have protruding studs or spikes264 of sufficient strength to penetrate the sheets 204, 206,208 beingpressed into to create the glob 258/insert 260 combination. The inserts260 may be constructed of a variety of materials compatible with theadhesive and/or foam. Additionally, the inserts 260 may be usedindependently of and/or without the glob 258 material. Other embodimentsof inserts 260 are shown in FIGS. 98 and 99. FIG. 98 shows a wire frametriangular pyramid shaped insert 260 pressed into a sheet 204, 206, 208,or embedded into a glob 258. FIG. 99 shows a solid triangular pyramidshaped insert adhering to a sheet 204, 206, 208, or embedded into a glob258. Some of the various qualities of the inserts 260 are discussedfurther below.

The inserts 260 may be either hollow or solid depending on weight, cost,and the material requirement. Though only a single large sphere is shownin FIG. 55, it is anticipated that a plurality of smaller inserts 260could be used in each glob 258 to add structural integrity to the glob258.

The inserts 260 may have a continuous surface, as shown in FIG. 55,which allows for ease of production and stronger insert 260 units. Theinserts 260 may also have a perforated surface, which, depending on thesize of the perforations, could allow the glob 258 material to seep intoand better bind with the inserts 260. If the inserts 260 are usedwithout a glob 258, the perforations could allow air to pass through theinserts 260 and thus increase air flow through the plenum. Also, theinserts 260 may have a frame like or cage exterior, as shown in FIG. 57.This would add the least amount of weight to the panel and allow forgreatest integration between the insert 260 and the glob 258, or, ifused independent of the glob 258 the greatest air flow. The cage surfacewould, all things equal, also be the weakest of the surfaces, which mustbe accounted for with increased strength via other measures, e.g.stronger material or increased thickness of the cage, using the cagesurfaced insert 260 in a glob 258, and/or increasing the number of cagesurfaced inserts 260 used compared to the number of continuous surfacedinserts 260 used in the same situation.

The inserts 260 may have a smooth surface, as shown in FIG. 55, whichwould allow for easier manufacture, but such a smooth surface woulddecrease the ability of the glob 258 material to adhere to the insert260 and, in many shapes, would provide no mechanical adhesion betweenthe insert 260 and the adjacent sheet 204, 206, 208. If the adjacentsheet 204, 206, 208 is of a type that must remain un-punctured, or has alayer one that must remain un-punctured or intact, smooth surfacedinserts 260 may be necessary. If used without globs 258, smooth surfacedinserts 260 would preferably be adhered to the sheets 204, 206, 208 withadhesive or bonding. Additionally, the insert 260 may have a texturedsurface, for example, with dimples or bumps. This would aid in theinsert 260 bonding to the glob 258 if used with a glob 258, but wouldpotentially increase manufacturing time and limit the types of materialsused.

In another, and likely a preferable embodiment, the inserts 260 wouldhave a surface that included spikes 264, barbs, or other suchprojections. The spikes 264 would aid in the glob 258 bonding to theinsert 260, allowing the glob 258 material to envelop the spikes 264,and would provide a means for mechanical adhesion of the insert 260 tothe adjacent sheets 204, 206, 208. The spikes 264 would need to be of aquantity, thickness, length, and with a sufficiently sharp apex and/oredge, that the spike 264 would perforate but not damage the adjacentsheets 204, 206, 208. The spikes 264 would preferably protrude or extendfrom the surface of the insert 260 a length less that the thickness ofthe adjacent sheets 204, 206, 208, so that the spike 264 would not fullypierce through the sheets 204, 206, 208, from one surface to the other.The spikes 264 could be uncoated, or could be coated with a cement,vinyl, or resin coating that melts with the heat generated from thefriction during insertion, but that solidifies when cooled. The coatingwould provide extra adhesion between the spike 264 and the sheets 204,206, 208.

There are a variety of shapes that the inserts 260 may take, dependingon if used with glob 258 material or not, and other panel 2, 202requirements, like strength, air flow, and weight. The inserts 260 maybe shaped as spheres or spheroids, cylinders, pyramids, rectangular ortriangular prisms or other polyhedrons. The inserts 260 may have one ormore bores or passageways extending partially or fully through the shapeto allow passage of air or glob 258 material.

The inserts 260 may also be shaped, as shown in FIG. 58 for example, asa barricade 266. This design provides three points of contact with eachsheet, while using minimal material and providing significant airpassage. A spike 264 normal to the sheets 204, 206, 208 may be formed oneach of the six terminal ends of the barricade 266, or the terminal endsthemselves may be sharpened, barbed, or otherwise function as spikes264. Additionally, if used with globs 258, the barricade 266 shape canbe easily and fully integrated in the glob 258, providing structuralsupport and spacing. The three arms of the barricade 266 can each beoriented at 90 degrees to the other two arms, or the arms can intersectat acute and/or obtuse angles to form taller or shorter barricades 266,and thus more or less spacing between the two sheets 204, 206, 208.

The inserts 260 may also have an elongate mid-section 268 that extendsand spaces top and bottom portions 270, 272 of the insert 260 from eachother. One embodiment, shown in FIG. 59, adopts a spindle type design,with disc shaped top and bottom portions 270, 272 spaced apart by amiddle rod 268. The top and/or the bottom portions 270, 272 could havecleats, barbs, or spikes 264 to aid in mechanically attaching the insert260 to the adjacent sheets 204, 206, 208, and could additionally oralternatively be attached to one or both sheets 204, 206, 208 with anadhesive.

The inserts 260 may also extend completely through one or more of thesheets 204, 206, 208. See, for example, FIGS. 60-62. As shown in FIGS.60 and 61, these through inserts 274 could be as simple as one or morethin rods 276 that extend through the middle sheet 206, both upwardlyand downwardly, into both the upper and the lower plenums 212, 214. Therods 276 could be used with or without the glob material 258. The rods276 could serve a spacing function for the globs 258, easily slicingthrough the uncured glob 258 material and contacting the inwardly facingsurface of the top or bottom sheet 204, 208 as the panel 202 is pressedtogether. The panel 202 could also be pressed further, pressing the rods276 into the top and bottom sheet 204, 208 as the entire panel 202 ispressed together, thereby providing a direct mechanical connectionbetween the top, middle, and bottom sheet 208. In the embodiment shown,a plurality of rods 276 would be used with a single glob 258.

The rods 276 may be smooth sided, the least expensive and easiestembodiment to manufacture. Alternatively or additionally, the rods 276may have vertical ridges around the axis of the rod 276, have horizontalribs or rings up the length of the rod 276, have a helical ridgetwisting up the length of the rod 276, and/or have a textured surface276.

The through inserts 260 like the rod 276 can be forced, screwed, orpunched through the sheet 206 after the sheet 206 is formed.

In another embodiment, the sheet 206 may be formed or molded around thethrough insert 260, whereby the through insert 260 is integrated intothe sheet 206 when the sheet 206 is formed. For example, FIG. 62 showsan integrated through insert 260 where the middle sheet 206 is formedaround the insert 260. The insert 260 has an extended spindle shape withan expanded contact surface 278 on upper and lower surface of the middlesheet 206. The expanded contact surface helps distribute force from thetop 204 or bottom sheet 208 to the middle sheet 206, and maintain thethrough insert 260 in a fixed vertical position with respect to themiddle sheet 206. In the embodiment shown, the through insert 260 alsohas a preferably disc shaped top and bottom portion 270, 272, contactingthe inward facing surfaces of the top and bottom sheets 204, 208, andlimiting their respective inward movement. The top and bottom portions270 of the through insert 260 may have cleats, barbs, or spikes, 264and/or adhesive applied.

The molded through or integrated insert 260 may also have a cage orperforated surface. For example, a cylinder with a cage surface could beintegrated into the middle sheet 206 when the sheet 206 is formed. Insuch an embodiment, the cylinder shaped through insert 260 would projectout of the top and bottom of the middle sheet 206. The cylinder shapedthrough insert 260 could then easily encase and integrate with a glob258 deposited on the bottom sheet 208 and on the top side of the middlesheet 206 in one simple step.

In another embodiment of a through insert 260, as shown in FIGS. 63 and64, a nail shaped through insert 260 can be used. The nail shapedthrough insert 260 could, for example, be driven through the middlesheet 206 in a downward direction, anchored by a disk shaped top portion270 to the rod 276 on a top surface of the sheet 206. As shown, theinserts 260 can be driven both upwards and downward through the samemiddle sheet 206. The leading end of the insert 260 may extend all theway through the opposing top or bottom sheet 208, and, as shown, theleading bottom end of the insert 260 could be pressed or crimpled belowthe lower surface of the bottom sheet 208, or a disk shaped bottomportion 272 could be attached. In this manner, the middle and top andbottom sheets 208 are mechanically fixedly secured together.Additionally, or alternatively, the nail shaped through inserts 260 maybe driven into the top sheets 204 downward and into the bottom sheets208 upward, each toward the middle sheet 206.

Referring next to FIGS. 65 and 66, a matrix of an orthogonal frame 280of thin tubes or wires 282 consisting of metal, wire, fiberglass, carbonfiber, plastic or other suitable material, or combinations of suchmaterials assembled in three dimensional a grid pattern is shown. Suchpattern has a height of the desired spacing between sheets 204, 206, 208in the panel 2, 202, not counting any optional upper or lowerprojections or spikes 264 intended to be inserted into adjacent sheets204, 206, 208. The orthogonal frame 280 is constructed of an upperlateral grid 284 and a lower lateral grid 286 joined together by aplurality of vertical straps 288. The frame 280 may be unitary, orjoined by gluing, welding, melting or otherwise fixedly joining theseparate members together. The lateral spacing of the separateindividual wires 282 is determined by the requirements of any spacingstructural elements 8 that are to be placed within the square orrectangular defined spaces 290, defined by spacing in the upper andlower lateral grids 284, 286.

The spacing structural elements 8 that are to be placed within thedefined spaces 290 can be wood blocks 210, plastic blocks 210, permeablematerial or organic, inorganic material or plastics or compositematerial of a combination of organic and/or inorganic material such as awood fibrous material in a resin or adhesive or steamed wood materialand adhesive, or glob 258 material.

The orthogonal frame can have spikes 264 that are designed to beembedded in the adjacent sheets 204, 206, 208 when pressed in the panel2, 202 production. The upper or lower terminal edge of the spikes 264may be flat, rounded, smooth, sharp, or barbed, depending on themechanical adhesion requirements.

The spacing structural elements 8, whether a solid or semi-solidadhesive or foam, will preferably have adhesive applied or have adhesivecharacteristics such that the spacing structural elements 8 willpreferably bond to adjacent sheets 204, 206, 208 and transfer structuralstress from one sheet 204, 206, 208 to the other.

As shown in FIG. 66, the defined space 290 may be filled by either asolid or a semi-solid material that has been compressed to take therough shape of the defined space 290. Specifically, FIG. 66 shows theplacement of a spacing structural element 8 comprising a block 210 ofmaterial placed within the orthogonal frame. This block 210 could be ofsolid or permeable or semi-solid material of the desired thickness suchthat the upper and lower edges can strongly adhere to the adjacentsheets 204, 206, 208, without voids, when the adjacent sheets 204, 206,208 are pressed together. Such spacing structural elements 8 can be ofwood, wood composite material, wood steamed composite material,plastics, permeable material, plastic blocks 210, plastic blocks 210with a matrix of voids such as open cell foams. The material wouldpreferably be capable of transferring the desired structural stress fromone sheet 204, 206, 208 to the other. In a further embodiment a glob 258could be deposited in the defined space 290 of the orthogonal frame 280.

It is to be noted that if the orthogonal frame 280 was of sufficientstrength, it could, by itself, function as the spacing structuralelement 8 connecting the two adjacent sheets 204, 206, 208 to oneanother without requiring the addition of a separate block 210 or glob258 in the defined space 290. Such an embodiment would preferablyinclude a plurality of diagonal truss members 292, described furtherbelow.

While in one embodiment of the orthogonal frame 280, a block 210 or glob258 is intended to be placed into the defined space 290, according toanother embodiment, as shown in FIGS. 67 and 68, the spacing structuralelement 8 may be unitary or bonded with the orthogonal frame 280. FIG.67 shows a three dimensional extruded or bonded orthogonal frame280/block 210 assembly. Each spacing structural element 8 can be solidor hollow and is attached on the top and the bottom with lateral straps292 to the adjacent spacing structural element 8. The spacing structuralelements 8 incorporated in this assembly may be hollow, and mayadditionally have an array of voids such that the flow of air isenhanced through the spacing structural elements 8 as well as around thespacing structural elements 8.

The lateral straps 292 between the spacing structural elements 8 in thisembodiment can be of the same material or a different material as thespacing structural elements 8. The lateral straps 292 can bemanufactured integrally or bonded/attached to construct the orthogonalframe 280. The spacing structural element 8 blocks 210 in thisembodiment are preferably a dimension of between 2″×2″ to 8″×8″ with aheight of between ½″ to 4″. The spacing structural elements 8 may alsobe rectangular shaped with the same dimensional constraints. The spacingstructural elements 8 are most desirably spaced from 2″ to 12″ betweeneach other. FIG. 68 shows the same bonded orthogonal frame 280/block 210with the bonded solid inserts 260 hashed for better visualization.

The three dimensional frame/block assembly would preferably be coveredwith adhesive on the top and bottom and attached to the two adjacentsheets 204, 206, 208—one on the bottom and one on the top and theadhesive cured. The adhesive would be compatible with the materialsbonded and of sufficient quantity for structural stress transfer.

In a production method utilizing a related design, FIG. 69 shows amethod of production which could be used as shown in a continuousmanufacturing arrangement or as a partial manufacturing arrangement.

This method provides for the separate lateral grids 284, 286 to be used,preferably without the vertical straps 288 as a net 294. The lateralgrids 284, 286 in this embodiment are preferably of a plastic materialwith a spacing of ¼″ to 1″ and a thickness of between 12 gauge to 40gauge. The separate lateral straps 292 are connected in a continuousgrid that is utilized to place the spacing structural elements 8 betweenthe two layers of grid material 284, 286. Adhesive is either applied tothe grids 284, 286 during its manufacture and is inherently connected toall fibers, or adhesive is applied before placing the spacing structuralelements 8, or adhesive is applied to the spacing structural elements 8,or some combination thereof. Regardless of the manner of adhesive, thespacing structural elements 8 are now connected in a manner of spacingfrom one another as previously described above to the upper and lowergrids 284, 286, so that the spacing structural elements 8 relativespacing from one another is fixed. Then net 294 of spacing structuralelements 8 can be maneuvered or moved down an assembly line where twosheets 204, 206, 208 are then adhered to the spacing structural elements8 with adhesive and or mechanical means. For example, spikes 264 may beused as above also to mechanically connect the upper or lower grids 284,286 to the respective adjacent sheet 204, 206, 208.

As shown in FIGS. 70-72, in another related embodiment, a twodimensional orthogonal matt 296, similar to the separate lateral grids284, 286, may be used to simultaneously attach the spacing structuralelements 8 to the sheets 204, 206, 208, and provide increased strengthto the sheets 204, 206, 208. The matt 296 is preferably constructed frommetal, although some plastics or composites may also be utilized. Thematt 296 is shaped in rectangular or square patterns, and preferablyinclude tab protrusions or tabs 298 that are either bent in a firstdirection, e.g. down (see FIG. 72), to penetrate a wood or woodcomposite block 210 or in a second opposite direction, e.g., up, topenetrate the sheet 204, 206, 208 that is to be laid on the top andsecured to the assembly. The tabs 298 can have smooth edged points, asshown, or jagged or barbed edges. The tabs 298 overlapping the blocks210 can all be directed into the block 210, as shown, or one or more ofthe tabs 298 in this location of overlap can also be directed away fromthe block 210 and toward the adjacent sheet 204, 206, 208. The matt 296can be used with or without additional adhesive which could be spread onthe matts 296 and/or blocks 210. The matts 296 could be on both the topand the bottom of the blocks 210, as shown in FIG. 70.

FIG. 71 shows a detail of the metal belt 300 of the orthogonal matt 296used to connect the spacing structural element 8 to the sheets 204, 206,208. Ideally, a bottom matt 296 is laid down and pressed into the bottomsheet 208, with the tabs 298 of the bottom matt 296 that are directedinto the bottom sheet 208 entering and attaching to the bottom sheet208. The spacing structural elements 8 are placed in the desiredlocation on the bottom sheet 208/bottom matt 296 and pressed into place.The tabs 298 of the bottom matt 296 are directed into the spacingstructural elements 8 entering and attaching to the spacing structuralelement 8. Next, the process is repeated with a top matt 296 laid downon the top sheet 204 (or bottom surface of the middle sheet 206 formulti-plenum panels 202) and pressed into place. The top sheet 204 isthen placed over the bottom sheet 208, with the tabs 298 of the top matt296 aligning over the spacing structural elements 8, and the entirepanel is then pressed into place into the desired overall thickness. Formulti-plenum panels 202, the process is repeated for the top surface ofthe middle sheet 206 and the top sheet 204.

The spacing structural elements 8 in this embodiment are preferablybetween 2″×2″ and 8″×8″ in width, and preferably ½″ to 4″ in height, andmay be, for example, square or rectangular shaped. The matts 296 wouldbe constructed to match the dimensions of the spacing structuralelements 8. The tabs 298 would be of a size and spacing that would meetthe structural stress transfer requirements without compromising theintegrity of the belt 300. The belt 300 could be ⅛″ to 1″ wide.

Tuning next to FIG. 73, this figure shows a possible interlockingmechanism that may be used to better attach adjacent panels 2, 202 whenassembled in the field, that may be utilized with multiple embodimentsof spacing structural elements 8, including those with utilizingorthogonal frames 280 and orthogonal matts 296. For example, in anembodiment using the orthogonal matts 296, the surface of the spacingstructural elements 8 along an outer edge of the panel 2, 202 may have aprotrusion 302 that fits into a mating indention 304 in a surface ofspacing structural elements 8 along an outer edge of an adjacent panel2, 202. Two adjacent edges of the panel 2, 202 could have spacingstructural elements 8 with protrusions 302, and the other two oppositeadjacent edges on the panel 2, 202 could have spacing structuralelements 8 with mating indentions 304. A typical design for theinterlocking mechanism is shown in the figure, although the interlockingmechanism can take the shape of rectangular tongue and grove or bevelededges. This interlock mechanism of spacing structural elements 8 can beutilized in any of the spacing structural elements 8 in the variousembodiments of single and multi-plenum panels 2, 202, and not only forthe orthogonal frames 280 and matts 296.

Turning now to FIGS. 74-80 a variation of the orthogonal frame 280 isshown, whereby a system of truss members 306 may be integrated in theorthogonal frame 280 to create a three dimensional truss matrix 308.While only a four by four grid section of the truss matrix 308 is shownfor better visualization, it is anticipated that the truss matrix 308will cover the entire horizontal span of the sheets 204, 206, 208. Thetruss matrix 308 could function alone as the spacing structural element8, to join at a defined separation adjacent sheets 204, 206, 208 andcreate the plenums 212, 214. The truss matrix 308 may also be used withseparate blocks 210, globs 258, or other spacing structural elements 8.Because of the diagonal truss members 306, though, it is not necessaryto have blocks 210 or globs 258 for shear stress transfer as this can bedone through the plurality of diagonal truss members 306 and the threedimensional truss matrix 308. As shown in FIG. 80, each apex 310, wherethe truss members 306 meet, may be crowned with a spike 264 to penetrateand mechanically attach the truss matrix to an adjacent sheet 204, 206,208.

The dimensions of the truss matrix 308 can vary, but are preferablybetween 2″ and 12″ in lateral spacing between adjacent lateral wires 282or straps 292 running in a parallel direction in the upper of lower grid284, 286, with the height preferably between 1″ to 6″. The grid of thetruss matrix 308 does not have to be square, but could be, for example,be rectangular too.

The orthogonal frame and/or the truss members can be made out of metal,wire, plastics, carbon fiber, fiberglass, and other suitable materials.It is probable that this may be the preferred embodiment used to attachtwo adjacent sheets 204, 206, 208 to each other in either the single ormulti plenum panels 2, 202. This embodiment offers the advantages ofease of production and assembly, low expense, potentially no organicmaterial exposed to the plenums, and potentially no curing times foradhesives.

In one embodiment, as shown in FIG. 74, the truss members 306 may beused independent of the orthogonal frame 280, to fix two adjacent sheetsto one another. This three dimensional space truss could be used with orwithout globs 258. When used with globs 258, they would preferably beplaced coincident with the apex 310 regions.

Turning next to FIGS. 81-83, an alternative method of constructing thespacing structural elements 8 between sheets 204, 206, 208 in amulti-plenum panel 202 is shown. Instead of blocks 210, a matrix ofpreferably single layered, branched, unitary/one piece/or bonded,engineered perforated members 120 could be utilized to separate thesheets 204, 206, 208 while providing the necessary air flow, orthogonalintersecting flow paths, and structural stress transfer. FIG. 81 shows agrid of perforated I shaped members 125.

The members 120 can be constructed of plastics, composites, carbonfiber, fiberglass, metal and can be extruded or formed and fusedtogether into the desired shape. The ends of members 120 can incorporatethe interlocking mechanism shapes shown in FIG. 73, such that adjacentexterior faces of the resulting panel 2, 202 would have an interlockingmechanism into the adjacent panel 2, 202 when assembled in the field.

The matrix members 120 could have a height of ½″ to 4″ and the width ofthe members could be from ¼″ to 4″ wide. The spacing of members could befrom 2″ to 10″ and could be square or rectangular.

FIG. 82 shows a matrix of truss shaped members 130. FIG. 83 shows amatrix of truss members 130 with spaced diagonal members, or “skiptruss” members 136. The attributes described in FIG. 81 are alsoapplicable to the truss shaped members 130, 136.

In a further embodiment, shown in FIGS. 84-93, the spacing structuralelements 8 may also be directly molded into the middle sheet 206 of amulti-plenum panel 202. That is, the spacing structural elements 8 in,e.g. block 210 shapes, separating the sheets 204, 206, 208 in themulti-plenum panels 202 can be fashioned as part of the middle sheet 206from pressing a formable material such as metal, including aluminum andother metals, formable plastics, especially plastics after heating, anduncured layer of wood composite material and resin. In any case, thelayer of formable sheet material is placed in a press and the blocks 210are pressed in two mating mold halves such that the sheet 204, 206, 208and blocks 210 become an integral member after hardening or curing inthe mold.

FIGS. 84 and 85 show a sheet 204, 206, 208, preferably a middle sheet206, with a series of block 210 shaped spacing structural elements 8that have been molded by pressing two mold halves together to the formdesired shape and thickness of the sheet 206 and “bulged” blocks 210.The blocks 210 are hollow on the inside, and have no base. The verticalsides 312 of the blocks 210 extend preferably orthogonally from themiddle sheet 206, and connect to a lateral cap 314. The blocks 210 couldbe filled with an insulation foam 316 or other type of insulatingmaterial. Though a block 210 shape is used in this embodiment, all othermoldable shapes of spacing structural elements 8 could also be employedin this molded middle sheet 206 embodiment. FIG. 86 shows a section ofthe middle sheet 206 with molded block 210 shaped spacing structuralelements 8. FIGS. 87 and 88 show the underside of the molded sheet 206.Again, any moldable material with sufficient structural strength couldbe used to mold the integral sheet 206 and spacing structural elements 8including metal, plastics, carbon fiber, fiberglass and a composite mixof wood fibers and resin or a mix of steamed wood fibers such as is usedin the production of Masonite.

Additionally, the presses could be designed such that a single sheet 206could be molded so that the spacing structural elements 8 extend bothupwards and downwards from the same middle sheet 206. FIGS. 89-92 show asheet 206 of metal, plastic, wood fiber or other structural moldablematerial that has been molded with spacing structural elements 8protruding in both directions perpendicular to the plane of the sheet206. The resulting sheet 206 contains the middle sheet 206 and thespacing structural elements 8 for both the upper plenum 212 and thelower plenum 214 all unitary and shaped together. FIG. 91 shows asection of a molded block 210 for the upper plenum 212 along with theadjacent but staggered molded block 210 for the lower plenum 214. FIG.92 shows the bottom view of the middle sheet 206 molded with spacingstructural elements 8 extending both upwardly and downwardly into therespective upper and lower plenums 212, 214.

In a variation of this embodiment, as shown in FIG. 93 two mirror moldedsheets 318 each with spacing structural elements 8 molded thereto, butonly extending in a single direction, are combined to make a singlemiddle sheet 206. The combined molded spacing structural elements 8 arealigned with one another and extend in opposite upward and downwarddirections. The two mirror molded sheets 318 are arranged parallel toone another, with the respective spacing structural elements 8 in thetop sheet 318 extending upwardly and the spacing structural elements 8in the bottom sheet 318 extending downwardly. The two mirror moldedsheets 318 are attached to one another with adhesive and/or mechanicalmeans to create a single middle sheet 206. Insulation is preferablyplaced in the space formed between the two structural spacing elements 8before attaching the two mirror molded sheets 318 to one another. Thisway, the molded spacing structural elements 8 extending into therespective plenums 212, 214 can be vertically aligned with one anotherto better aid in transfer of stress from the top sheet 204 to the bottomsheet 208. As shown in the figure, the voids defined between the twoblocks 210, for example, may be filled with insulation material tominimized heat transfer, and potentially increase structural integrity.

Turning now to FIG. 54 an assembly of a multi-plenum panel 202, withlayers of lining and different types of sheets 204, 206, 208 is shown.Given the possible materials and their best and most useful applicationsfor the sheets 204, 206, 208 to construct a multi-plenum panel 202 theconfiguration described below might be a typical multi-plenum panel 202,though other combinations a possible depending on the requirements andusage of the multi-plenum panel 202. The layer of the top sheet 204 hasa ½″ layer of wood product—either OSB or plywood for the subfloorsheathing function of the multi-plenum panel 202. The bottom facing orbottom surface of the top sheet 204 has either a sealer or radiantlayer. The middle sheet 206 is constructed from rigid insulation bondedto two facings of plastic or metal. The middle sheet 206 could also beconstructed of ¼″ plywood. The bottom sheet 208 has an exposed facingcomprised of a thin coat of gypsum with a paper facing suitable fortypical drywall finishing applications bonded to a ¼″ sheet of OSB orPlywood. The sheets 204, 206, 208 could be spaced from and attached toone another by the spacing structural elements 8 described above,including blocks 210, globs 258, spacers 262 and/or inserts 260. Theconfiguration in this embodiment does not have any organic materialsexposed to the air moving through the plenums, which minimizes thepotential for mold or fungal growth if by chance there was anycondensation in the air distribution.

Turning now to FIGS. 94-97, the bottom or second sheet 6 of a singleplenum panel 2 is shown with round tube shaped applications of ribbonsor strips 320 of a semi-liquid/semi-solid adhesive and/or foam appliedthereon as the spacing structural elements 8. The diameter of the strips320 of adhesive and/or foam is preferably between ½″ to 3″ and thespacing is preferably between 2″ to 12″. FIG. 95 shows the adjacentfirst or top sheet 4 with strips 320 of adhesive and/or foam applied towith the same specifications as to the second sheet 6, but preferablyarranged orthogonally. FIG. 96 shows the two sheets 4, 6 about to beplaced together. There may be spacers 262 applied to the second sheet 6before the application of the top first sheet 4 to insure the correctfinished thickness of the panel 2 assembly. Additionally, spacers 262can be placed around the perimeter and interior between the adhesivestrips 320 to insure the desired thickness when pressed. The spacers 262can consist of pressed metal shapes that penetrate one sheet 4, 6 whenpressed in and with a protrusion that penetrates the other sheet 4, 6when the other sheet 4, 6 is pressed into the panel 2 assembly. Thespacers 262 can also be blocks 210 of wood or plastic that can beadhered to one or both adjacent sheet surfaces or can be used withoutadhesion to be removed later. FIG. 97 shows an assembled single plenumpanel 2 with spacing structural elements 8 in the form the ribbons,tubes, or strips 320 of adhesive/and or foam after being pressed andcured.

Similarly, the matrix for the single plenum panel 2 can be assembledfrom a matrix of spacing structural elements 8 consisting of hollowtubing 322 made from metal, plastic, fiberglass, composites, or othermaterials in an extruded or fused or assembled form. The tubing 322matrix members would adhere to each other and to the two sheets 4, 6 toconstruct the panel 2. The tubes 322 could also be perforated with holesto enhance air flow. The strips 320 or tubing 322 form of spacingstructural elements 8 could also be used for multi-plenum panels 202,but would potentially decrease absolute unobstructed orthogonal flowpaths, instead allowing sinusoidal flow paths in both lateraldirections—over and under the elongate spacing structural elements 8attached to the lower 208, 206 and upper 206, 204 sheet respectively.

Wherefore, I claim:
 1. A multi-plenum structural panel comprising: a topsheet, a middle sheet, and a bottom sheet, each sheet being parallel tothe other two; a first plurality of spacing structural elements fixedlyattaches the top sheet to the middle sheet, and a second plurality ofspacing structural elements fixedly attaches the middle sheet to thebottom sheet, such that a yield strength of an assembled multi-plenumstructural panel is greater than a sum of individual yield strengths ofthe top, the middle, and the bottom sheets; an upper plenum defined by afirst spacing between the top sheet and the middle sheet; a lower plenumdefined by a second spacing between the middle sheet and the bottomsheet; the spacing structural elements, comprised of the first and thesecond plurality of spacing structural elements, being formed such thata plurality of spaced apart unobstructed pathways are created in eachplenum for air to move from at least one edge of the multi-plenumstructural panel to at least one of an opposite and an adjacent edge ofthe multi-plenum structural panel in each plenum; wherein spacingstructural elements on a first portion of an exterior perimeter of thepanel have interlocking shapes that interlock with shapes on spacingstructural elements on a second portion of the exterior perimeter of thepanel; and at least one unobstructed pathway in the upper plenum isorthogonal to at least one unobstructed pathway in the lower plenum. 2.The multi-plenum structural panel in claim 1, wherein the spacingstructural elements are molded and of unitary construction with themiddle sheet.
 3. The multi-plenum structural panel in claim 1, whereinthe spacing structural elements have spikes that protrude into one ofthe top sheet, the middle sheet, and the bottom sheet.
 4. Themulti-plenum structural panel in claim 1, wherein the spacing structuralelements are inserts that one of have a barricade shape, have a cagedsurface, have spikes disposed on the surface, are hollow, or areperforated.
 5. The multi-plenum structural panel in claim 1, wherein thespacing structural elements are a matt and block assembly, the mattcomprising a plurality of tabs, wherein the tabs insert into one of ablock, the top sheet, the middle sheet, and the bottom sheet.
 6. Themulti-plenum structural panel in claim 1, wherein the spacing structuralelements comprise a three dimensional space truss and spikes arepositioned at apexes where a plurality of diagonal truss members meet;and a plurality of further unobstructed pathways, each further pathwaybounded at least partially by the spacing structural elements, intersectin one of the upper plenum, the lower plenum, and both the upper andlower plenum.
 7. The multi-plenum structural panel in claim 1, whereinthe spacing structural elements comprise a branched and perforatedengineered matrix member.
 8. The multi-plenum structural panel in claim1, wherein each of the top sheet, the middle sheet, and the bottom sheetis one of multilayered, comprised of multiple materials, and has acoating or a lining, and the bottom sheet is multilayered with at leastone layer of drywall material.
 9. The multi-plenum structural panel inclaim 1 wherein the top, the middle, and the bottom sheets are eachbetween 0.125 inches and 1.0 inches in thickness, not including thethickness of any molded or unitary spacing structural elements, and arebetween 3.0 and 4.5 feet by between 6.0 and 12 feet in planardimensions, and are made of one of plywood, Oriented Strand Board, andmedium-density fiberboard.
 10. The multi-plenum structural panel inclaim 1, wherein the spacing structural elements are comprised ofmaterial one of extruded and deposited in globs.
 11. The multi-plenumstructural panel in claim 10, wherein inserts are inserted into theglobs.
 12. The multi-plenum structural panel in claim 1, wherein thespacing structural elements are inserts that pass through the middlesheet.
 13. The multi-plenum structural panel in claim 12, wherein themiddle sheet is molded around the inserts.
 14. A multi-plenum structuralpanel comprising: a top sheet, a middle sheet, and a bottom sheet, eachsheet being parallel to the other two; a first plurality of spacingstructural elements fixedly attaches the top sheet to the middle sheet,and a second plurality of spacing structural elements fixedly attachesthe middle sheet to the bottom sheet, such that a yield strength of anassembled multi-plenum structural panel is greater than a sum ofindividual yield strengths of the top, the middle, and the bottomsheets; an upper plenum defined by a first spacing between the top sheetand the middle sheet; a lower plenum defined by a second spacing betweenthe middle sheet and the bottom sheet; the spacing structural elements,comprised of the first and the second plurality of spacing structuralelements, being formed such that a plurality of spaced apartunobstructed pathways are created in each plenum for air to move from atleast one edge of the multi-plenum structural panel to at least one ofan opposite and an adjacent edge of the multi-plenum structural panel ineach plenum; and wherein at least one of (a) the spacing structuralelements are an orthogonal frame and (b) the middle sheet comprises atleast one of: (i) spacing structural elements extending through themiddle sheet and toward both plenums, (ii) two molded sheets attached toone another with spacing structural elements on each molded sheetaligned and extending in two opposite directions, and (iii) insulatingmaterial filling a void in the spacing structural elements.
 15. Themulti-plenum structural panel in claim 14, wherein the orthogonal framefurther comprises one of blocks and globs.
 16. The multi-plenumstructural panel in claim 14, wherein the orthogonal frame furthercomprises blocks that are one of unitary with and molded to theorthogonal frame.
 17. The multi-plenum structural panel in claim 14,wherein the spacing structural elements are a matrix truss comprisingthe orthogonal frame and diagonal truss members.
 18. The multi-plenumstructural panel in claim 14, wherein spacing structural elements on afirst portion of an exterior perimeter of the panel have interlockingshapes that interlock with shapes on spacing structural elements on asecond portion of the exterior perimeter of the panel.